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Arctic Cat Sno Pro 120, Service Manual

The Arctic Cat Sno Pro 120 is the perfect snowmobile for young riders. Packed with power and agility, this sleek machine guarantees an exhilarating ride. For a comprehensive understanding of its intricacies, don't forget to download the free Service Manual from our website. Master your machine like a pro!

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2-12

FS177A

19. Remove the spark plug wires from the plugs; then

disconnect the two-wire plug-in for the coolant tem-

perature sensor (located below the ignition coil).

FS193A

20. Remove the harness wrap and disconnect all igni-

tion/main harness connectors; then remove the cable

tie (if applicable) securing the harness to the coolant

tank/heat exchanger hose and secure the harness out

of the way.

FS181

21. Place an absorbent towel beneath the hose to collect

any coolant from the exchanger; then disconnect the

front heat exchanger hose.

22. Remove the four cap screws securing the upper bear-

ing bracket to the upper support plate (account for

the two bracket plates); then secure the steering post

to the headlight support bracket.

FS183A

23. Remove the exhaust manifold from the engine.

Account for the flange nuts and gaskets.

24. Remove the cap screw and lock nut (A) and lower

cap screw (B) securing the PTO-side engine mount-

ing bracket to the chassis.

742-205B

25. Remove the four cap screws (C) securing the PTO-

side bracket to the engine; then remove the bracket.

Account for the torque bumper.

26. Remove the two cap screws (D) securing the front

engine plate to the chassis; then remove the cap

screw (E) securing the MAG-side engine mounting

bracket to the chassis.

27. Tip the engine forward and support the engine in a

position to gain access to the clamp securing the

coolant hose to the thermostat housing; then loosen

the clamp and remove the hose.

FS184A

28. Carefully remove the engine out the MAG-side of

the chassis.

Summary of Contents for Sno Pro 120

Page 1: ...s and snowmobile decals display the words Warning Caution and Note to emphasize impor tant information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death A CAUTION identifies unsafe practices which may result in snowmobile related damage Follow the directive because it deals...

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

Page 3: ...tions 1 8 Crankshaft Runout Repair Specifications 2 Stroke 1 9 Arctic Power Valve APV System Specifications 800 cc 1 9 Carburetor Specifications 570 cc 1 9 Electrical Specifications 1 10 Ignition Timing Specifications 2 Stroke 1 11 Drive System Specifications 1 12 Drive Clutch Driven Pulley Related Specifications 1 12 Drive System Components 1 12 Drive Belt Dimensions 1 12 Gear Case Performance Ca...

Page 4: ...ises wherein 91 octane gaso line is not available 87 octane gasoline can be substi tuted however do not prolong the usage of 87 octane gasoline as it will cause poor engine performance In many areas oxygenates are added to the gasoline Oxygenated gasolines containing up to 10 ethanol are acceptable gasolines Do not use gasolines containing methanol RECOMMENDED OIL 2 Stroke The recommended oil to u...

Page 5: ...re the most common way to increase engagement speed however by simply changing the cam arms to a lighter weight from the heavier sea level cam arm you will gain some engagement speed Other more complicated methods exist such as engage ment notches and changing the position of the cam arm center of gravity in relation to the roller This is called tucking the weight and can be used but like the enga...

Page 6: ...nsion to collapse much quicker and change the angle of the track to the snow A more gradual angle will tend to raise the snowmobile up on the snow rather than digging into it Many possible variables and adjustments to the rear sus pension exist depending on snow conditions riding style and type of terrain These adjustments can be made to indi vidualize the snowmobile to the riding style of the ope...

Page 7: ...em outlet with a clean cloth 7 On the 2 stroke with the ignition switch in the OFF position A Disconnect the high tension leads from the spark plugs then remove the plugs connect them to the leads and ground them on the cylinder heads B Pour 29 5 ml 1 fl oz of SAE 30 petroleum based oil into each spark plug hole and pull the recoil starter handle slowly about 10 times C Install the spark plugs and...

Page 8: ...rm with an all temperature grease 10 On liquid cooled models check the coolant level and all coolant hoses and connections for deterioration or cracks Add properly mixed coolant as necessary 11 On the 570 cc clean the engine cooling fins and vents 12 On electric start models charge the battery then connect the battery cables making sure to connect the positive cable first Test the electric start s...

Page 9: ...commended mileage for this inspection is between 100 and 300 miles Jet carburetors according to average tempera ture type of gasoline being used and altitude 570 cc Check drive belt deflection drive clutch driven pulley alignment Adjust track tension and alignment Check throttle cable tension Check oil injection pump adjustment 2 stroke Check engine idle Check coolant level Check chain case gear c...

Page 10: ...o Turbo 0 0011 0 0016 0 0006 0 0010 Piston Pin Diameter Non Turbo Turbo 0 8658 0 8661 0 9447 0 9449 Piston Pin Bore Diameter Non Turbo Turbo 0 8662 0 8664 0 9449 0 9451 Piston Pin Connecting Rod Non Turbo Small End Clearance Turbo 0 0004 0 0010 0 0004 0 0009 Piston Ring End Gap 1st 2nd Oil 0 0059 0 0138 0 0118 0 0177 0 0078 0 0275 Piston Ring Groove Clearance 1st Top 1st Bottom 2nd Oil 0 0059 0 00...

Page 11: ... the center place indicator on center of bearing as shown at point E Maximum runout at any of the three measuring points is 0 002 Arctic Power Valve APV System Specifications 800 cc 0735 516 Carburetor Specifications 570 cc NOTE The above specifications are production cal ibrations For high altitude carburetion and drive sys tem settings refer to the jet chart on the snowmobile belt guard For opti...

Page 12: ...Unit 10 15 DC Volts red blue low power red black high power black low power black high power 800 cc Normally Open Ignition Ignition Coil Primary Secondary 0 24 0 36 ohm 5040 7560 ohms black white high tension wire white blue high tension wire Charge Coil 1 8 8 13 2 ohms black red green red Charge Coil 2 8 8 13 2 ohms brown white green red Lighting Coil 0 08 0 12 ohm yellow yellow Ignition Timing S...

Page 13: ...g shown with engine warm Ignition timing is not adjustable 500 cc BTDC 13 2000 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 217 800 cc BTDC 16 5 2000 RPM 0 072 0746 516 ...

Page 14: ...ring Torque Bracket Drive Belt Engagement RPM Peak RPM Top Gear Bottom Gear Chain Pitch F 800 LXR Sno Pro LTD 0 5000 Yellow White 73 5g Black Blue 44 40 0627 083 42 4600 81 8200 21T 38T 84 F 1100 LXR Sno Pro 0 5000 Gold 60g Black Blue 42 36 0627 081 28 3000 85 8600 22T 48T 90 F 1100 Turbo LXR Sno Pro 0 5000 Yellow White 85g Black Blue 44 40 0627 082 38 4000 76 7800 22T 37T 84 M 800 Sno Pro LTD HCR...

Page 15: ...22 125 128 131 134 137 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 83 85 88 91 93 96 99 101 104 107 109 112 115 117 120 59 61 80 83 85 88 90 93 95 98 101 103 106 108 111 114 116 58 62 77 80 82 85 87 90 92 95 97 100 102 105 107 110 112 57 63 75 77 80 82 ...

Page 16: ...4 96 98 101 22 48 0 458 90 88 90 93 95 98 100 103 105 108 21 41 0 512 86 98 101 104 106 109 112 115 117 120 20 38 0 526 84 101 104 107 109 112 115 118 121 123 21 38 0 553 84 106 109 112 115 118 121 124 127 130 20 35 0 571 82 110 113 116 119 122 125 128 131 134 23 40 0 575 86 110 113 116 120 123 126 129 132 135 22 37 0 595 84 114 117 120 124 127 130 133 136 139 23 36 0 639 84 123 126 129 133 136 14...

Page 17: ... 6 75 18 50 Bearcat XT 437 75 4 50 7 75 18 50 SKI SHOCK Model Collapsed Length Extended Length Stroke Piston Depth Bearcat 570 F Series T570 11 55 17 50 5 95 N A Bearcat XT 10 67 16 00 5 33 N A TZ1 LXR Turbo 11 53 16 72 5 19 1 50 XF STD 12 80 18 70 5 90 7 72 F Sno Pro XF Sno Pro 12 80 18 40 5 60 7 72 M STD 11 81 17 90 6 09 1 29 M Sno Pro 12 00 17 55 5 55 6 68 HCR Turbo 12 30 17 80 6 59 7 36 F STD ...

Page 18: ...ki Spindle 35 Ski Wearbar 96 in lb Ski Ski Handle 54 in lb Handlebar Adjuster Block Stan dard Post 15 Handlebar Adjuster Sno Pro Post 15 Steering Support Mounting Block 96 in lb Steering Post F XF M 1000 Steering Stop Bracket 43 Steering Tie Rod Steering Post 35 Steering Tie Rod Steering Arm 20 Steering Post Cap Riser Block 120 in lb Steering Post M 800 SP HCR Mounting Bracket 20 Tie Rod Steering ...

Page 19: ... 34 Rear Arm Rail 20 Idler Arm Rear Arm 40 Front Shock Rail 40 Rear Shock Front Arm Idler Arm 30 Rail Support Rail 20 Front Shock Front Arm 40 Limiter Strap Rail Support 72 in lb REAR SUSPENSION M XF cont Item Secured to Torque ft lb Rail M Turbo HCR Rail Brace 12 Rear Idler Wheel Rear Idler Wheel 80 in lb Rear Shock Link Front Arm Idler Arm 30 Front Arm Rail 40 Skid Frame Tunnel 40 F Wear Strip R...

Page 20: ...1 18 NOTES ...

Page 21: ...0 Assembly Schematic 800 cc 2 26 Engine Removing Installing Bearcat Z1 XT TZ1 2 28 Assembly Schematic 1100 cc 2 42 Engine Removing Installing F M XF 1100 2 44 Assembly Schematic 1100 cc 2 60 Engine Servicing 570 cc 2 63 Engine Servicing 500 cc 2 79 Engine Servicing 800 cc 2 95 Engine Servicing 1100 cc 2 114 Troubleshooting Engine 2 Stroke Carbureted 2 137 Troubleshooting Engine 2 Stroke EFI 2 139 ...

Page 22: ...ing 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 and heat shield TZ064A 5 Remove the cap screws and lock nuts securing the heat shield to the chassis Account for the U nut clip 6 Remove the cap screws securing the recoil starter Note the position of the ground wire for ass...

Page 23: ...ng 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 bracket to the chassis then remove the bracket 16 Remove the cap screws and lock nuts securing the headlight support bracket to the front upper frame then remove the bracket and account for the mount ing hardware 17 Loosen the carburetor flange clamps and...

Page 24: ...ght then rotate 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 cap screws securing the engine plate to the engine then remove the plate FZ014 Installing 1 Install the engine plate to the engine with four cap screws Tighten to 36 ft lb FZ025 2 Install ...

Page 25: ... NOTE Place a cloth beneath the oil injection pump to contain any oil spilled during the bleeding process 7 With the throttle cable and fuel lines properly routed install the flange clamps to the intake flanges then install the carburetors and secure with the clamps FZ006 8 Install the headlight support bracket and secure the bracket with the cap screws and lock nuts 9 Install the rear MAG side en...

Page 26: ...ecure with the wire with the lock nut 18 Install the oil supply hose and low oil sensor wire to the oil reservoir and install the reservoir Secure with the cap screws and lock nuts 19 Secure the wiring harness to the chassis with the wir ing harness clamp cap screw and lock nut Tighten securely FZ012A 20 Install the grommets into the spark plug opening of the engine shroud then connect the spark p...

Page 27: ...then start 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 torque of the drive clutch 29 Secure the console to the steering support with the torx head screws and tighten the screws securely then close the left side and right side access panels and close...

Page 28: ...2 8 Assembly Schematic 570 cc 570 ENG12 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 ...

Page 29: ...2 9 2 570ENG12 ...

Page 30: ...sonator then remove these components from the engine compartment Account for the two exhaust gaskets NOTE Disconnect the negative cable from the bat tery 4 With the seat adjusted to its lowest position remove the self tapping screw from the right side seat adjust ment track then remove the seat ZJ100A 5 Remove the torx head screws securing the handlebar close off panel then remove the panel 6 Remo...

Page 31: ...E Note the routing and securing locations of the hose for assembling purposes 14 Loosen the flange clamps securing the throttle body assembly to the flange then move the throttle body assembly forward and disconnect the oil injection cable control rod from the oil injection pump FS178A NOTE Remove the clamps from the intake flanges to avoid damage during engine removing 15 Loosen the clamps securi...

Page 32: ...t plates then secure the steering post to the headlight support bracket FS183A 23 Remove the exhaust manifold from the engine Account for the flange nuts and gaskets 24 Remove the cap screw and lock nut A and lower cap screw B securing the PTO side engine mount ing bracket to the chassis 742 205B 25 Remove the four cap screws C securing the PTO side bracket to the engine then remove the bracket Ac...

Page 33: ...Loctite 609 Tighten to 20 ft lb FS190A 3 Install the MAG side engine mounting bracket to the engine with the cap screws F coated with blue Loctite 243 Tighten to 23 ft lb 742 205B 4 Install the front lower engine plate to the engine with four cap screws G coated with blue Loctite 243 Tighten to 50 ft lb 5 Place the engine into the engine compartment from the MAG side then tip the engine forward an...

Page 34: ...o the chassis then install the four cap screws C coated with blue Loc tite 243 securing the bracket to the engine Tighten all mounting hardware to 23 ft lb 10 Connect the coolant hose to the outlet of the front heat exchanger and secure with the hose clamp FS196A 11 Route the ignition harness and the coolant tempera ture sensor two wire connector between the coolant tank and the chassis then conne...

Page 35: ...ll move approximately 1 8 in before the oil injection pump control arm begins to move 16 Install the two coolant hoses to the MAG side and PTO side of the crankcase below the exhaust ports then tighten the coolant hose clamps and the throttle body flange clamps FS271A 17 Apply a thin coat of high temperature silicone seal ant to each exhaust port then install the exhaust gas kets 18 Apply a thin c...

Page 36: ...A 26 Install the air silencer onto the throttle bodies making sure the dual intake boot is properly positioned and seated NOTE To aid in installing the air silencer remove the air silencer cover and work the intake boot over the throttle body from inside the silencer FS201A 27 Place the front bumper assembly with spar panels into position on the snowmobile then secure the front and rear spar panel...

Page 37: ...onsole into position on the headlight sup port bracket do not secure the console with the torx head screws at this time then connect the console main harness plug in 39 Install and close the left side and right side access panels and the hood 40 Start the engine and warm up to operating tempera ture then verify that all components are functioning properly and that coolant is circulating through th...

Page 38: ...2 18 Assembly Schematic 500 cc 500CC1A12 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 ...

Page 39: ...2 19 2 500CC2A_12 ...

Page 40: ...e sensor from the expansion chamber 2 Remove all springs securing the expansion chamber and resonator then remove the expansion chamber and resonator 3 Remove the cap screw from the driven pulley and slide the driven pulley along with the drive belt off the driven shaft Account for alignment washers 4 Using Drive Clutch Bolt Tool remove the cap screw and high collar washer securing the drive clutc...

Page 41: ...securing the air intake boot to the throttle bodies and pull the air intake boot forward enough to gain access to the throttle body assembly Remove and retain the clamps 15 Loosen the flange clamps securing the throttle body assembly to the intake flanges and disconnect the oil injection control rod from the throttle body then loosen the clamps securing the throttle body coolant hoses Disconnect t...

Page 42: ...e out of the engine compartment NOTE If replacing the engine make sure to remove the engine support plate exhaust manifold three coolant hoses and oil injection control rod for instal lation on the new engine Installing NOTE If the engine was replaced make sure to install the existing engine support plate exhaust manifold three coolant hoses and oil injection con trol rod on the new engine Tighten...

Page 43: ...pump Secure with the clamp NOTE After securing the oil hose to the oil pump remove the bleed screw to allow any air in the hose pump to be released PC179A 17 Connect the MAG side throttle body coolant hose then secure with a clamp 18 Connect the TPS then lower the throttle body assembly into the engine compartment 19 Place the throttle body assembly into position and secure with the flange clamps ...

Page 44: ... 51 ft lb NOTE Before installing the drive clutch be sure to wipe both the crankshaft and clutch mounting tapers clean using a clean towel 34 Install the driven pulley on the driven shaft then install the drive belt see Section 6 35 Install the driven pulley see Driven Pulley in Sec tion 6 then check drive belt deflection see Section 6 Install the rear belt guard 36 Place the hood into position on...

Page 45: ...2 25 2 NOTES ...

Page 46: ...2 26 Assembly Schematic 800 cc 800_12_1 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 ...

Page 47: ...2 27 2 800_12_2 ...

Page 48: ...e screws C securing the left and right side rear spar panels to the seat support tubes Remove the screws D secur ing the front spar panels to the front bumper then remove the spar panels NOTE On the turbo model only the console and cap screws E securing the left front spar panel have to be removed 4 Remove the seat see Section 8 5 Disconnect oxygen sensor connector then remove the springs securing...

Page 49: ...8 then on the non turbo models remove the air silencer see Sec tion 3 12 Remove the two cap screws securing the headlight support bracket to the right side upper frame TZ070A 13 Disconnect the ECU harness connectors the coolant temperature sensor A and the oil pressure switch B then remove the cable ties and clips securing the harness and gasline hoses to the left side upper frame TZ072A ZJ090A NO...

Page 50: ...ut TZ071A 15 Remove the five cap screws and lock nuts securing the support gusset left side upper frame to the steer ing support then remove the support bracket and left side upper frame ZJ024A NOTE On the turbo model after removing the five cap screws and lock nuts account for the clip from the cap screw A securing the two gasline hoses and air intake assembly to the steering support then remove ...

Page 51: ...emaining hoses from the separator tank TZ081A NOTE On the non turbo TZ1 note the location of the resonator mounting pin for installing purposes 20 Remove the separator tank assembly from the right side upper frame then disconnect the two coolant hoses from the water pump TZ079A 21 On the turbo model use a suitable clamping device to close off the coolant return hose and remove it from the turbocha...

Page 52: ...rew TZ078A 24 With the cover removed move the steering post assembly to the right side of the engine compart ment NOTE Steps 25 30 are for the turbo model only 25 Loosen the clamps securing the hose to the intake pipe and throttle body TZ085A 26 Remove the two cap screws securing the intake pipe to the cylinder head cover then remove the remain ing cap screw securing the pipe to the left side of t...

Page 53: ...ody assembly along with the two flanges TZ090A 31 Remove the positive cable from the starter motor 32 On the non turbo models disconnect the harness plug ins from the ignition coils A and camshaft timing sensor B ZJ094A NOTE With the main harness plug ins discon nected secure the harness up and out of the way from the engine 33 On the non turbo models loosen the clamps securing the throttle body a...

Page 54: ...3 993A NOTE Lift the engine at an angle with the PTO side upward to allow clearance for the oil reservoir to be removed from the chassis with the engine Installing NOTE Engine lift points consist of the four threaded holes on the front and rear corners of the cylinder head or on the exhaust manifold 741 658A 743 993A NOTE Install the engine with the PTO side directed upward at an angle to allow pr...

Page 55: ... filter then tighten to 15 ft lb 5 Install the starter motor cable with cap screws then tighten securely 6 Connect the wiring harness connectors to the coolant temperature sensor A and the oil pressure sensor B then install the heat exchanger coolant hose to the thermostat outlet C and oil cooler hose to the outlet D with the clamps Tighten securely ZJ090B NOTE Steps 7 10 are for the non turbo mod...

Page 56: ...ap screws to the cover to 18 ft lb and the remaining cap screw to the head to 37 ft lb then tighten the intake hose clamps securely TZ085B TZ099A NOTE Place the upper frame into position and install the clip securing the wire harness to the steer ing support gusset TZ098A 13 Install the lower air silencer to the turbocharger and tighten the hose clamp A securely then with the upper frame in positi...

Page 57: ...dy coolant return hose is secured ZJ018B TZ075A 17 Connect the harness plug ins to the ignition coils A and camshaft sensor B then route the main harness to the proper connector locations and secure with cable ties as noted during removing ZJ094A 18 On the turbo model install the spark plug wires and the throttle cable to the throttle body pulley and bracket then tighten the jam nuts securely 19 O...

Page 58: ...the oxygen sensor NOTE Steps 25 28 are for the turbo model only 25 Install the upper heat shield then connect the coolant return hose to the turbo and secure with the hose clamp TZ060A NOTE To aid in coolant bleeding procedure do not secure the upper heat shield to the manifold at this point 26 Connect the air bypass hose and the air bypass con trol valve hose to the intake pipe and secure with th...

Page 59: ...oolant is visible at the bleed screw then tighten the bleed screw and add coolant to the coolant reservoir Full Cold line 744 032A 37 If the engine oil was drained remove the filler cap from the oil reservoir and add the recommended amount of oil using the following procedure If the engine oil was not drained start the engine and allow it to run for 5 minutes Inspect for any signs of cool ant leak...

Page 60: ...until no air is visible or heard at the bleed screw Tighten the bleed screw and add coolant to the reservoir if necessary NOTE If the coolant level in 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 engine 39 Start the engine and allow it to run for five minutes Inspect for any s...

Page 61: ...2 41 2 Engine Torque Patterns 1100 cc 1100TorquePattern12 ...

Page 62: ...2 42 Assembly Schematic 1100 cc 1100ccJAG12 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 ...

Page 63: ...2 43 2 1100ccZ1RV10 ...

Page 64: ...does not have to be removed from the chassis Proceed to Ser vicing Top Side Components 1 Remove the seat see Section 8 then disconnect the bat tery cables negative cable first and solenoid harness NOTE On the LXR models disconnect the seat heater harness connector 2 Remove the retaining nut from the neck of the gas tank and the two screws securing the upper console and disconnect the wires from th...

Page 65: ... skid plate remove the drain plug from the oil reservoir After the oil has drained install the drain plug with a new O ring if necessary and tighten to 15 ft lb PC065 11 Using a suitable vacuum pump remove the coolant from the coolant oil separator tank then loosen the clamp and remove the hose from the tank and the lower heat exchanger Remove the coolant from the lower exchanger PC025A NOTE Steps...

Page 66: ...e brackets from the intercooler then carefully pry the intercooler out from the front brackets B and remove the intercooler with the air bypass valve and hoses PC056A NOTE At this point removing the front fascia will aid in engine removal PC540A 16 Remove the coolant return hose from the turbo charger then remove the screws securing the front heat shield to the chassis and rear heat shield CAUTION...

Page 67: ...e cap screws F or G securing the shock mounting bracket support to the shock mounting brackets then remove the cap screws C securing the lower front spars to the shock mounting brackets Remove the shock mounting bracket support and front spars accounting for the spar inserts NOTE On the turbo models the shock mounting bracket support left front spar and heat shield are removed as an assembly 20 Re...

Page 68: ... for the non turbo models only 25 Loosen the clamps securing the air silencer to the throttle bodies then disconnect the harness connec tor from the air temperature sensor and remove the air silencer PC033A 26 Disconnect the harness plug ins from the ignition coils A and camshaft timing sensor B ZJ094A NOTE With the main harness plug ins discon nected secure the harness up and out of the way from ...

Page 69: ...osen and remove the oil tank engine breather hose then remove the cap screws securing the oil return hose from the engine Remove the oil return hose PC034A PC243 32 Remove the two cap screws securing the elbow fit ting of the oil supply hose to the engine then secure the hose and fitting up and out of the way PC036A NOTE On the non turbo install Engine Lift Plate On the turbo models secure a suita...

Page 70: ...e the cap screws lock nuts and carriage bolt securing the PTO side chassis sup port With the fuse block out of the bracket remove the support with the front belt guard PC060A NOTE After removing the PTO side chassis sup port re install the cap screw securing the rear PTO side engine to chassis mount bearing bracket to secure the bearing PC209A 38 Remove the cap screws securing the PTO side engine ...

Page 71: ...ling 1 Carefully lower the engine into the chassis position ing the engine so it clears the PTO side rear engine chassis mount and on the turbo models the turbo charger clears the front of the chassis then lower the engine until the studs of the lower front engine chas sis mount are into the mounting holes of the chassis PC040A PC047A 2 Tip the engine forward enough to install the cables to the st...

Page 72: ...he MAG side engine to chassis mount using the two cap screws coated with blue Loctite 243 E Tighten the upper screw to 40 ft lb and the lower screw to 50 ft lb 8 Install the MAG side chassis support and secure with the cap screws coated with blue Loctite 243 F G H Tighten the rear cap screws to 25 ft lb and the front cap screws to 12 ft lb NOTE Note the location and orientation of the reso nator s...

Page 73: ...harness properly routed secure the harness to the engine with cap screw and routing clamp then tighten the cap screw securely PC037A PC206A NOTE Steps 15 17 are for non turbo models only 15 Install the throttle bodies and secure with the clamps then install and secure the throttle body coolant tank and the throttle body cylinder head hoses ZJ018A 16 Connect the harness plug ins to the ignition coi...

Page 74: ...d secure the throttle body coolant hoses to the coolant tank and cylinder head PC211A 20 With the spark plug wires routed properly install the spark plug caps to the spark plugs NOTE Make sure the caps are firmly seated on the plugs 21 Install and secure the throttle cable to the bracket and pulley noting the routing of the cable then connect the idle speed control SNO 741A 0743 992 22 With the wi...

Page 75: ... illustration 746 292B NOTE For assembling purposes apply a small amount of silicone or tape to keep the inserts secured into the spar tubes and use new lock nuts and cap screws when securing the spars to the chassis A Secure the front spars with the steering bracket to the shock mounting brackets using two cap screws inserts and new lock nuts Tighten to 23 ft lb NOTE On the turbo models install t...

Page 76: ...post with the caps and four cap screws Tighten the cap screws to 15 ft lb NOTE Connect the handlebar harness to the main harness connector and secure the connectors to the harness at the PTO side steering support PC061A 28 Install the throttle cable into the lever then verify the throttle lever free play is within specification 0741 518A NOTE Steps 29 32 are for the turbo models only 29 Install th...

Page 77: ...lb NOTE Steps 33 34 are for the non turbo models only 33 Position the exhaust pipes and resonator into the chassis and install and secure the MAG and PTO exhaust flanges with new gaskets to the cylinder head with the flange nuts Tighten evenly to 17 ft lb 34 With the resonator properly installed to the chassis support install the spring securing the resonator to the mounting tab NOTE With the exha...

Page 78: ...before securing the upper console 41 Connect the battery cables positive first and the ground wire to the battery then connect the solenoid harness to the solenoid PC021A 42 Install the seat see Section 8 43 Elevate the front of the snowmobile until the tunnel heat exchangers are angled upward towards the engine 44 Open the coolant bleed screw on the cylinder head then add coolant to the reservoir...

Page 79: ...neck until no air is visible or heard at the bleed screw Tighten the bleed screw and add coolant to the reservoir if necessary NOTE If the coolant level in 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 engine 52 Start the engine and allow it to run for five minutes Inspect for ...

Page 80: ...2 60 Assembly Schematic 1100 cc 1100ccJAG12 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10 ...

Page 81: ...2 61 2 1100ccZ1RV10 ...

Page 82: ...2 62 Engine Torque Patterns 1100 cc 1100TorquePattern12 ...

Page 83: ...NOTE Special tools are available from the Arctic Cat Service Parts Department Disassembling 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 five cap screws securing the front exhaust side shroud to the cylinder head Account for the special washers MD0276 NOTE Keep the special mounting hardware w...

Page 84: ...pecial washers MD0277 MD0067 8 Remove the rubber insulator grommet from the crankcase then remove two Phillips head cap screws securing the ignition timing sensor MD0075 MD0073 9 Remove the three Allen head cap screws securing the stator and remove it along with the timing sensor then carefully pull the wires through the hole in the crankcase MD0072 MD0076 CAUTION To prevent damage to the cranksha...

Page 85: ...der head to the cylinders then remove the cylinder head Discard the cylinder head gasket MD0289 14 Remove the four 6 mm nuts and eight 10 mm nuts securing the cylinders to the crankcase NOTE Using a felt tip marker mark the cylinders as to MAG side and PTO side for assembling Also mark the pistons at this time MD0087 MD0086 15 Remove the cylinders making sure to support the pis tons so they are no...

Page 86: ...f the piston pin bearing washers must seat to the bearing MD0251 MD0208 NOTE Always replace with new piston rings and as a complete set Note the identification on the tapered side of each ring for installation purposes 726 306A MD0271 17 Remove the two Allen head cap screws securing the oil injection pump then remove the pump Account for an O ring MD0090 ...

Page 87: ...then remove the crank shaft assembly from the upper crankcase half making sure to hold both ends of the crankshaft to keep the bearings and seals from falling off Account for bear ings and a C ring Cleaning and Inspecting CYLINDER HEAD 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chambers being careful not to nick scrape or damage the com bustion chamber...

Page 88: ...he end of the old ring to a 45 angle and to a sharp edge Using the sharpened ring as a tool clean carbon from the ring grooves Be sure to posi tion the ring with its tapered side up 3 Inspect each piston for cracks in the piston pin and skirt areas 4 Inspect each piston for seizure marks or scuffing If scuffing or seizure marks are too deep replace the piston 5 Inspect the perimeter of each piston...

Page 89: ...ankshaft with bearings in parts cleaning solvent 2 Inspect the bearings for wear scoring scuffing dam age or discoloration Rotate the bearings Bearings must rotate freely and must not bind or feel rough If any abnormal condition is noted replace the bearing FC039 3 Inspect the connecting rod bearings by rotating them The bearings must rotate freely and must not bind or feel rough If a connecting r...

Page 90: ...e bearing onto the PTO end making sure the dowel pin hole will align with the hole and pin in the crankcase AN151A REED VALVE ASSEMBLY 1 Inspect the reed valves stoppers and cages for cracks or any deterioration 2 Wash the reed valves stopper and cage assembly in parts cleaning solvent and blow dry 3 Inspect the reed stopper height Using a caliper mea sure the distance from the seat to the bottom ...

Page 91: ...e over several 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 squish gap Never mea sure across piston exhaust to carburetor side as the piston will rock and the reading won t be accurate Readings may vary from side to side NOTE Make sure the small...

Page 92: ...n remove the gauge and measure it with a micrometer AN061 2 The diameter measurement must be within 0 9056 0 9059 in CRANKSHAFT RUNOUT 0742 727 1 Using V Blocks support the crankshaft on the sur face plate NOTE The V blocks should support the crankshaft on the outer bearings 2 Mount a dial indicator and base on the surface plate Position the indicator contact point against the crank shaft location...

Page 93: ...positioned over its respective dowel pin in the crankcase then seat the crankshaft NOTE To check the bearing for proper position place the point of a sharp tool into the dimple found in the bearing race Strike the tool with the palm of the hand in either direction If the bearing moves it isn t positioned correctly and must be rotated until it drops onto the dowel pin NOTE Position the two center s...

Page 94: ... connecting rods with the arrow or indicator dot pointing toward the exhaust port then secure with an oiled piston pin Install new piston pin circlips with the open ends up or down MD0293 NOTE To aid in the circlip installation install the circlip to the inside of the piston before installing the connecting rod MD0248 11 Place the cylinder base gasket into position on the crankcase making sure the...

Page 95: ...stalling the four 6 mm and eight 10 mm nuts Tighten the 10 mm nuts in a criss cross pattern to 44 ft lb and the 6 mm nuts to 96 in lb MD0086 MD0087 14 Install a new cylinder head gasket and the cylinder head then install the eight cap screws and two flange nuts Tighten the cap screw in three steps to 19 ft lb using the pattern shown then tighten the flange nuts to 21 ft lb MS384 MS384 0738 291 15 ...

Page 96: ...e Loctite 243 then install and tighten them to 96 in lb MD0255 18 Place the stator wiring through the hole in the crank case then install the stator Lightly coat the three Allen head cap screws with blue Loctite 243 then tighten to 48 in lb MD0076 MD0274 19 Place the ignition timing sensor wiring through the hole in the crankcase then position the ignition tim ing sensor and install two Phillips h...

Page 97: ...old the starter cup tighten the flywheel cap screw to 50 ft lb MD0264 MD0278 23 Using Flywheel Spanner Wrench to hold the starter cup tighten the three cap screws from step 21 to 28 ft lb TZ067A 24 Using the six cap screws and the special washers install the rear intake side shroud Tighten the cap screws coated with red Loctite 271 to 96 in lb MD0277 25 Using the five 6 mm cap screws and the speci...

Page 98: ...oil injection pump driveshaft retainer MD0273 28 With a new O ring lightly coated with oil in place install the oil injection pump aligning the slot on the oil pump with the flat on the end of the oil injection pump driveshaft Tighten the Allen head cap screws coated with blue Loctite 243 to 48 in lb MD0294 29 Install the first set of intake gaskets coated with High Temp Sealant heat deflector rem...

Page 99: ...artment Disassembling 1 Remove the exhaust manifold from the 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 Spanner Wrench to secure the flywheel remove the flywheel cap screw and flat washer then remove the three starter pulley cap screws and remove the...

Page 100: ...late from the engine FC021 FC065 NOTE The stator plate screws had Loctite applied to the threads during assembly Using an impact driver apply a sharp blow to the head of each screw to break the Loctite loose before removal 7 Remove the spark plugs 8 Remove the cap screws with O rings securing the cylinder head then separate from the cylinders Account for the O rings 9 Remove the oil injection hose...

Page 101: ...Keep each piston with its rings keep each pis ton pin and bearing together as a set CM151 14 Remove the intake flanges and reed valve assem blies FC030 15 Remove the three cap screws securing the thermostat cap then remove the cap gasket and thermostat FC032 16 Remove the six screws securing the water pump cover to the crankcase and remove the cover Account for the O ring gasket and the alignment ...

Page 102: ... the crankshaft After removing the seals use care not to allow the bearings to slide off the crankshaft 24 Remove the oil injection pump water pump drive shaft from the lower crankcase half Account for the thrust washer on the outer end of the shaft CM159A NOTE When replacing the inner water pump seals use the recommended Water Pump Bearing and Seal Tool Kit only 25 Place the crankcase on the benc...

Page 103: ...he 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 maintain a low drill RPM If honing oil is not available use a lightweight petroleum based oil Thoroughly clean the cylinders after honing using detergent soap and hot water and dry with com pressed air then immediately apply...

Page 104: ...r wear 6 Inspect the sealing surfaces of the crankcase halves for trueness 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 indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots by continuing to move the hal...

Page 105: ...nd replace the crankshaft end NOTE Install the bearings by sliding each bearing onto the crankshaft making sure the dowel pin hole in the outer race is properly positioned and will align with its hole and pin in the crankcase CM161 REED VALVE 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 ...

Page 106: ...eces insert them down through the spark plug hole towards the PTO side and MAG side of the cylinder Push on the solder until they contact the inner cylinder bore 6 Pull the recoil rope and crank the engine over several 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 accu...

Page 107: ...on pin bore then remove the gauge and measure it with a micrometer The diameter measurement must be within 0 8661 0 8665 in Take two measurements to ensure accu racy AC092 CONNECTING ROD SMALL END BORE 1 Insert a snap gauge into each connecting rod small end 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 RUNOU...

Page 108: ...vent and compressed air and thoroughly clean the threaded holes of the crankcase and cylin ders to properly tighten NOTE When the use of a lubricant is indicated use Arctic Cat Synthetic APV 2 Cycle Oil 1 Apply a thin coat of grease to the inner seal lips of the water pump seal 2 Using the seal driver position the inner water pump shaft seal onto the seal driver and gently tap the seal down into p...

Page 109: ...rops onto the dowel pin 9 Position the two center seal rings with their end gaps 180 apart up on one and down on the other then apply a thin coat of High Temp Sealant to the entire bottom 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 FC071 10 Assemble th...

Page 110: ... O ring lightly coated with oil in place install the oil injection pump making sure the pump shaft slot and pump driven gear shaft align Secure with two screws coated with blue Loctite 243 Tighten the two screws to 96 in lb 17 Position the ceramic rubber seal retainer and seal into the back side of the water pump impeller with the ceramic face of the seal directed out CM168 18 Using a suitable too...

Page 111: ...carefully remove before proceeding 21 Position the O ring lightly coated with oil into the water pump cover then install the cover Secure with six screws then using the pattern shown tighten to 96 in lb FC134 0742 304 22 Noting the alignment dots install the thermostat housing with thermostat Secure the housing with cap screws and tighten to 96 in lb FC078A FC073 23 With new gaskets install the re...

Page 112: ...ected either up or down CM195B NOTE Install the circlip to the inside of the piston before installing the connecting rod 29 Rotate each piston ring until the ring ends are prop erly positioned on either side of the ring keeper then apply oil to the piston assemblies and cylinder bores Remove the rubber bands or hoses from the connect ing rods 30 In turn on each cylinder place a piston holder or su...

Page 113: ...inder care fully start and finger tighten all four cap screws while observing the cylinder O rings to make sure they remain in position Slowly place the head into position on top of the O rings Start and finger tighten the remaining cap screws being very careful not to move the cylinder head 36 From step 35 in two steps tighten the 8 mm cap screws to 19 ft lb using the appropriate pattern shown In...

Page 114: ...ads of the flywheel cap screw then finger tighten with a large flat washer DO NOT TIGHTEN AT THIS TIME FC080 42 Secure the starter pulley to the flywheel with three cap screws and using the spanner wrench tighten the cap screws evenly to 19 ft lb then tighten the fly wheel cap screw from step 41 to 50 ft lb FC081 43 Install the coolant supply hose to the water pump and cylinder hose then install t...

Page 115: ...Arctic Cat Service Parts Department Disassembling NOTE When disassembling top side components mark MAG side and PTO side components for assem bling purposes 1 Using the Flywheel Spanner Wrench to secure the flywheel remove the flywheel cap screw and washer then remove the three starter pulley cap screws and remove the pulley CM138 CM139 2 Install the Flywheel Puller Insert onto the end of the cran...

Page 116: ... and account for the har ness grommets CM141C NOTE For assembling purposes note the timing sensor with the white dot white connector is located in the upper mounting location of the crankcase IO016A 6 Remove the Allen head cap screws securing the sta tor to the stator plate Route the stator lead wire out of the crankcase then remove the stator assembly CM143A 7 Remove the cap screws securing the s...

Page 117: ...r the O rings NOTE When removing the cylinders place the engine on its intake flanges on a drain tray to allow residual coolant to drain from the cylinder crankcase water jacket 11 Remove the four nuts and four cap screws securing the cylinders to the crankcase then using a soft ham mer gently tap the cylinders and remove from the crankcase by lifting them straight up off their studs Account for g...

Page 118: ... the intake flanges Remove the intake flanges and reed valve assemblies IO014 16 Remove the lower union cap screw securing the lower check valve assembly to the crankcase then remove the two screws securing the oil injection pump to the crankcase Remove the pump retainer and O ring and account for the two gaskets from the lower union CM153A IO015A 17 Remove the four cap screws securing the thermos...

Page 119: ...blocks remove the cap screws securing the crankcase halves 23 Separate the crankcase halves by installing two crankcase cap screws in opposite corners leaving the heads approximately 1 4 in out Using a plastic ham mer and lifting on the ends of the crankshaft tap on each cap screw head until the case halves separate Remove the cap screws CM158 24 Lift the bottom half of the crankcase off the top h...

Page 120: ...ecting CYLINDER HEAD 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chambers being careful not to nick scrape or damage the com bustion chambers or the sealing surfaces 2 Inspect the spark plug holes for any damaged threads 3 Inspect the cylinder head for flatness using a straightedge and a feeler gauge Acceptable warpage must not exceed 0 002 in NOTE If t...

Page 121: ...cuffing or seizure marks are too deep to correct with the sandpaper it will be necessary to replace the piston 5 Inspect the perimeter of each piston for signs of excessive blowby Excessive blowby indicates worn piston rings or an out of round cylinder NOTE If synthetic oil is being used a certain amount of blowby may be visible under normal use CRANKCASE 1 Wash the crankcase halves in parts clean...

Page 122: ...od and crank 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 to assembly REMOVING INSTALLING OUTER CRANKSHAFT BEARINGS NOTE The end bearings are not pressed onto the crankshaft The bearings can be removed simply by sliding them off the crankshaft C...

Page 123: ...e engine 2 Simultaneously insert two pieces 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 several times while the solder is being held firmly in place 4 Remove both pieces of solder from the cylinder Using the micrometer measure the very end of the squeez...

Page 124: ...P 1 Place each piston ring in the wear portion above the exhaust 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 0196 in FC045 PISTON PIN AND PISTON PIN BORE 1 Measure the piston pin diameter at each end and in the center Acceptable piston pin measu...

Page 125: ...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 indicator and rotate the crankshaft slowly Note the amount of crankshaft runout total indicator reading 5 If runout exceeds 0 002 in at any of the checkpoints the crankshaft must be either straightened or replace...

Page 126: ...re the spring side of each seal faces inward 8 Apply oil to the crankshaft bearings then install the crankshaft into the upper crankcase half Be sure the alignment hole in each bearing is positioned over its respective retaining pin in the crankcase then seat the crankshaft IO019A NOTE To check the bearing for proper position place the point of a sharp tool into the dimple found in the bearing rac...

Page 127: ...coat of grease to the sealing surface of the oil injection pump water pump driveshaft then place the Oil Seal Protector Tool at the end of the shaft FS191 15 Rotate the oil injection pump water pump driveshaft while carefully pushing it through the oil and water pump seals until the driveshaft and crankshaft gears engage then remove the oil seal protector tool A from the end of the shaft IO025A 16...

Page 128: ...n secure the intake flange oil hoses to the oil pump and secure with the clamps IO021A IO022A 20 Install the coolant temperature sensor threads coated with white Loctite 575 and tighten to 18 ft lb then secure the sensor wire to the sensor with a cable tie CM172 21 Position the ceramic rubber seal into the back side of the water pump impeller with the ceramic face of the seal directed out CAUTION ...

Page 129: ...crankcase CM171A CM171B 25 Apply a thin film of low temp grease to the water pump cover O ring then position the O ring into the water pump cover With the alignment pins in place install the cover Secure with the screws using the pattern shown Tighten to 96 in lb 0742 257 26 With the bypass valve of the thermostat directed to the 12 o clock position install the thermostat and housing then in a cri...

Page 130: ...all the small end bearings Install a washer on each side of the connecting rod TZ068 NOTE The shoulder side of the washer must seat to the needle bearing CM172A 30 Place each piston over the connecting rod so the indi cator dot on each piston will point toward the intake exhaust ports then secure with an oiled piston pin NOTE The indicator dot is found on the piston dome CM173 31 Install the new c...

Page 131: ...cylinders by tightening the cylinder base nuts and cap screws to 44 ft lb in three steps using the pattern shown 0738 206 NOTE Always use new cap screws when installing the cylinders 35 Install the two cylinder O rings lightly coated with oil on the top of each cylinder making sure they are correctly positioned in the grooves FC077 36 Place new O rings lightly coated with oil onto each of the head...

Page 132: ...ute the stator harness through the opening in the crankcase then secure the stator to the stator plate with the Allen head cap screws coated with blue Loctite 243 Tighten to 96 in lb CM143A 41 Secure the upper ignition timing sensor white dot connector with cap screws coated with blue Loctite 243 Tighten to 48 in lb then install the wiring grommet into the notch of the crankcase IO049A 42 Secure t...

Page 133: ...ighten the flywheel cap screw from step 45 to 50 ft lb 48 Install the coolant inlet hose to the cylinder head and water pump then tighten the hose clamps securely CM181 NOTE At this time if the coolant temperature sen sor was removed install the sensor threads coated with blue Loctite 243 and tighten to 18 ft lb 49 Apply a thin coat of high temperature silicone seal ant to each exhaust port then i...

Page 134: ...ice Parts Department Disassembling 1 With the engine secured to a suitable engine stand remove the coolant drain plug allowing the remain ing coolant to drain from the engine ZJ028A 2 Remove the remaining coolant hoses then remove the clamps and hoses connecting the oil reservoir to the engine NOTE For assembling purposes note the location of the oil and coolant hoses 3 Remove the six flange nuts ...

Page 135: ...r to the engine Remove the starter motor ZJ028C 8 On the non turbo models remove the cap screws securing the two intake flanges to the cylinder head then remove the flanges ZJ029A 9 On the turbo models remove the four cap screws securing the manifold adapter assembly then remove the manifold TZ087A 10 Remove the three cap screws securing the thermostat cap to the engine then remove the cap and the...

Page 136: ...ve the four cap screws securing the oil scav enge pump to the engine then remove the pump and account for the remaining oil seal ZJ033A 13 To remove the flywheel first remove the cap screw and washer securing the flywheel to the crankshaft then using Flywheel Puller remove the flywheel ZJ034 14 Remove the flywheel key from the crankshaft then remove the starter gear ZJ036A 15 On the non turbo mode...

Page 137: ...ves in this sub section 18 Loosen but do not remove the tension adjuster bolt and washer A from the chain tensioner assembly Remove the two cap screws B securing the assem bly to the engine Remove the assembly ZJ038A 19 Remove the cap screws securing the camshaft covers to the cylinder head then remove the covers Remove both camshafts Account for the dowel pins 741 624A 20 Using a magnet or needle...

Page 138: ...note the location of the different length cap screws for assem bling purposes 24 Tip the engine upside down then remove the 28 cap screws securing the upper and lower crankcase halves Using a soft hammer gently tap around the bottom half until it separates NOTE Note the location of the different length cap screws for assembling purposes 25 After separating the crankcase halves account for two O ri...

Page 139: ... assembly purposes ZJ046A 30 Reinstall the connecting rod caps with cap screws into the rods then using a soft hammer gently tap the piston assembly out the top side of the cylinder ZJ044 31 Remove the oil separator plates for the lower crank case half and account for the eight Allen head cap screws ZJ047A 32 Remove the Allen head cap screws securing the pis ton cooling jets to the upper crankcase...

Page 140: ... Valve clearance must be within specifications ZJ105 NOTE When measuring valve tappet clearance on the exhaust valves rotate the engine until the decom pression pin of the valve tappet is activated then using a flat nosed punch carefully tap the decom pression arm until the decompression pin releases the tappet IO051A IO052B NOTE At this point if valve tappet clearances are within specifications s...

Page 141: ...2 121 2 SNO2152 ...

Page 142: ...2 122 SNO2153 ...

Page 143: ...ose off the intake ports of the cylinder head PISTON ASSEMBLY NOTE Whenever a piston rings or pins are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal tool remove any carbon buildup from the dome of the piston 2 Inspect the piston for cracks in the piston pin dome and skirt areas 3 Inspect the piston for seizure marks or scuffing NOTE If seiz...

Page 144: ...iston pin bore Piston diameter must be within 3 8568 3 8574 in for the non turbo and 3 8574 3 8580 in for the turbo If not the piston must be replaced Subtract this measurement from the measurement in step 1 Measurement must be within 0 0011 0 0016 in for the non turbo and 0 0006 0 0010 in for the turbo If the determined wear exceeds the limit indicated and the piston is within tolerance the cylin...

Page 145: ...ore or piston bore is badly worn or damaged replace pin connect ing rod or piston Cleaning Inspecting Measuring Cylinder Block 1 Wash the cylinder block in parts cleaning solvent 2 Check the head gasket surface of the cylinder for dis tortion 3 Using a straightedge and feeler gauge check surface at a total of 6 locations If distortion limit exceeds 0 002 in replacement of the block will be necessa...

Page 146: ... corresponding letters on the upper engine case are located to the upper left of the oil filter ZJ181B NOTE Always correspond the letters of the engine case with the case right side up and from left to right MAG to PTO Each row of letters is to be referred to the following Crankcase Stamping Crankshaft Stamping Balancer Shaft Journal Stamping Refer to the proper chart and select the correct bearin...

Page 147: ... Cat recommends that new gaskets seals and O rings be installed whenever assembling the engine NOTE For assembling purposes use oil dissolv able molybdenum disulfide grease as engine assem bly grease 1 Install one piston pin circlip into one of the pistons making sure the open end is directed either up or down Place the connecting rod in position making sure the identification number on the rod ca...

Page 148: ... proper bearings selected install the half bearings into the upper engine case then lubricate the bearing faces liberally with engine assembling grease taking care not to get any grease between the engine case and bearing NOTE Make sure the tabs of the bearings are prop erly seated to the notches in the upper engine case ZJ069A NOTE At this point remove the connecting rod caps 8 Lubricate the lips...

Page 149: ...he oil relief valve ZJ076A NOTE Prior to installing the oil relief valve make sure the valve is free and clear of any contaminants 14 With proper bearings selected install the counterbal ancer bearing halves into the upper engine case then apply a light film of engine assembly grease to the bearing surfaces 15 Rotate the crankshaft to the bottom dead center posi tion then install the rear counterb...

Page 150: ...p screws into the proper locations in the crankcase then with the torque pattern shown as numbered on the case tighten the cap screws only until snug 741 582A 23 For initial tightening of the engine case cap screws use this sequence A Cap screws 1 6 10 mm to 13 ft lb B Cap screws 7 24 8 mm to 120 in lb C Cap screws 25 28 6 mm to 96 in lb 24 For final tightening of the engine case cap screws use th...

Page 151: ...ft 28 Install the cam chain tensioner then install the wash ers between the engine case and guide tensioner and secure with two Allen head cap screws coated with blue loctite 243 Tighten to 84 in lb ZJ080 29 Position the pistons at the top dead center position by rotating the crankshaft until the keyway on the crankshaft is directed upward and aligned with the cylinder ZJ081A 30 Install the alignm...

Page 152: ...camshaft NOTE The exhaust camshaft must be installed first When installing the cam chain to the gear of the exhaust camshaft position the chain so no slack between the crankshaft gear and exhaust camshaft exists when the camshaft is installed All slack in cam chain must be on the side of the tension adjuster ZJ084 35 With the timing marks A on the face of the cam shaft gear properly aligned place ...

Page 153: ...ns then install the engine cover and secure with four cap screws and plastic washers Using the pattern shown tighten the cap screws to 120 in lb 741 580A NOTE At this point install the spark plugs 42 Place the starter gear on the crankshaft then install the flywheel key ZJ036A 43 Install the flywheel with the cap screw and washer Using the flywheel holder wrench from Flywheel Puller tighten the ca...

Page 154: ... and oil pressure sensors were removed install the sensors and tighten in the following sequence A coolant tem perature sensor to 15 ft lb and B oil pressure sensor to 10 ft lb ZJ090A 47 Install the coolant hose inlet fitting and secure with the two cap screws Tighten to 84 in lb ZJ031B 48 Install a new thermostat then install the cover and secure with the two cap screws Tighten to 84 in lb NOTE M...

Page 155: ...ssembly of the non turbo engine is complete NOTE Steps 53 59 are for the turbo models only 53 If removed install the mounting bracket to the turbo charger then with the backing plate properly posi tioned as noted during disassembling secure the bracket to the turbo with the lock nuts and finger tighten only TZ063A 54 Install the lower heat shield onto the turbocharger and exhaust manifold with the...

Page 156: ...d secure the hoses with the hose clamps 743 991A 59 With the turbocharger secured install the oil feed pipe with the banjo bolts and two new crush washers on each side of the union Tighten to 11 ft lb 744 771B NOTE Make sure when installing the oil feed pipe that the correct banjo bolt is securing the pipe to the engine and turbocharger as noted in disassembling ...

Page 157: ...7 Impulse hose 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 obstruction replace vent hose 5 Remove obstruction replace in line fuel filter 6 Replace repair clean fuel pump 7 Replace connect impulse hose 8 Troubleshoot clean replace carburetors 9 Repair r...

Page 158: ...l hose obstructed 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 2 Remove obstruction replace repair fuel hose 3 Replace head gasket s service cylinders head 4 Tighten cylinder head cap screws 5 Tighten spark plugs 6 Replace impulse hose 7 Service replac...

Page 159: ...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 Replace regulator hose 4 Replace check valve 5 Service replace fuel pump connections wires 6 Replace service hose 7 Remove obstruction replace vent hose 8 Remove obstruction replace pick up valve s 9 Repair replace damaged worn engine components 10 Replace E...

Page 160: ...ugs 4 Service 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 LED trouble code 2 Fuel pressure too high 3 Injector faulty 4 Throttle position sensor faulty 5 Air silencer obstructed 1 Service replace problem component 2 Replace regulator hose 3 Replace...

Page 161: ...n and tight 2 Repair replace connect wiring harness 3 Move switch to UP position replace throttle control 4 Adjust throttle cable tension replace throttle body assembly 5 Clean replace spark plugs 6 Turn ignition switch ON and OFF listen for stepping motor ISC valve operation 7 Replace ECU 8 Replace sensor Problem Engine Does Not Start No Fuel at Cylinders Condition Remedy 1 Gas tank empty 2 Gasol...

Page 162: ...air replace damaged worn engine components 7 Replace water pump thermostat Problem Engine Backfires Condition Remedy 1 Check Engine light illuminated 2 Spark plugs fouled damaged 1 Check codes replace problem component 2 Clean replace spark plugs Problem Engine Stops Suddenly Condition Remedy 1 Gas tank empty 2 Spark absent 3 Check Engine light illuminated 4 Fuel filter s obstructed 5 Fuel pressur...

Page 163: ...Chart 1100 cc 3 14 Liquid Cooling System 500 800 cc 3 14 Liquid Cooling System 1100 cc 3 15 Cooling System Schematics 3 17 Recoil Starter 500 cc 3 19 Recoil Starter 570 800 cc 3 20 Air Silencer 570 cc 3 21 Air Silencer F5 LXR 3 22 Air Silencer Bearcat T Series 1100 cc Non Turbo 3 23 Air Silencer F M XF 1100 cc Non Turbo 3 27 Air Silencer 1100 cc Turbo 3 27 Turbocharger Intercooler F XF M 1100 cc T...

Page 164: ... Water Pump Bearing and Seal Tool Kit FS237A 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 the two cap screws securing the oil injection pump and pull the oil pump from the engine Leave the pump hose and cable attached 3 Remove the cap screw secur...

Page 165: ...rankcase FC123 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 ASSEMBLING 1 Wipe the seal area clean using a clean rag FC125 2 Position the inner seal onto the seal driver spring side towards the crankshaft Gently tap into posi tion FC126A 3 Using a small ...

Page 166: ...he tool FS233A 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 lubricated with oil on the oil injection pump and retainer 8 With the O ring in place on the oil injection pump align the pump with the shaft then install the pump Secure with two cap sc...

Page 167: ... then install the 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 Position the O ring into the water pump cover then install the cover Install the cap screws then using the pattern shown tighten to 96 in lb FC134 0742 304 Water Pump 800 cc DISASSEMBLING N...

Page 168: ...en remove the 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 B securing the oil pump to the engine Remove the pump FS220A NOTE Leave the two upper check valves secured to the pump FS221A 4 Remove the cap screw securing the impeller Account for the...

Page 169: ...een the retainer 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 in the crankcase FS228 9 Using the hooked end of the long seal driver pull the inner seal free of the crankcase FS229 ASSEMBLING 1 Thoroughly clean the seal surfaces of the crankcase 2 Positi...

Page 170: ...tector Tool 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 Position the shim A on the oil pump end of the shaft then with the O ring in place on the retainer B install the oil injection pump retainer IO026A 8 With the O ring in place on the oil inje...

Page 171: ...5 10 Apply sealant to the crankcase seam then install the alignment pins into the crankcase if removed FC133A 11 Position the O ring into the water pump cover then install the cover Install the cap screws then using the pattern shown tighten to 96 in lb 0742 257 Water Pump 1100 cc REMOVING 1 Drain the engine coolant see the appropriate Liquid Cooling System in this section 2 Remove the water bypas...

Page 172: ...allation tool install the oil seal E with the spring side facing the bear ing 8 Place the mechanical seal D into the inner housing then using the appropriate sized installation tool drive the seal into the housing until the lip of the seal is properly seated 9 Install the ceramic seal C onto the impeller shaft with the ceramic face of the seal facing away from the impeller 10 Install the impeller ...

Page 173: ...ing temperature and full cranking RPM and the decompression system active With the spark plugs removed install the compression tester gauge with adapter into the spark plug hole then with the throttle valve in the full open position crank the engine over to get the psi reading Compression should be 120 psi NOTE Verify both cylinder compression readings are within 10 of each other Changing Oil Filt...

Page 174: ...nate immediately on the standard gauge or after the three seconds on the pre mium gauge NOTE If the warning icon does not illuminate place the ignition switch in the OFF position and repeat step 11 then place the ignition switch in the ON posi tion and repeat step 12 13 If the warning icon illuminates from step 12 start the engine The warning icon should go out within five seconds If it does let t...

Page 175: ...eed to step 14 NOTE If the warning light does not go out shut the engine off immediately and repeat step 11 then place the ignition switch to the ON position and repeat step 13 14 Shut the engine off and pour the remaining amount 0 9 l or 1 U S qt of recommended oil into the oil reservoir then proceed to check the oil level to ver ify and finalize the procedure Testing Oil Pressure 1100 cc The Low...

Page 176: ...securing the hood Remove the hood 2 With the engine cool remove the coolant cap then using a suitable coolant vacuum pump remove as much coolant as possible from the filler neck PC225A 3 Remove all springs securing the expansion chamber then with the expansion chamber removed loosen the clamp securing the lower coolant hose behind the engine Remove as much coolant as possible using the coolant vac...

Page 177: ... perature of 36 C 34 F Follow mixing recommen dations of the manufacturer of the coolant NOTE At this point on the F Series secure the con sole with the torx head screws INSPECTING COOLANT HOSES AND CLAMPS All coolant hoses and connections should be checked annually for deterioration cracks and wear All coolant hoses and clamps should be replaced every four years INSPECTING THERMOSTAT 1 Inspect th...

Page 178: ...d screw and add coolant to the reservoir if necessary NOTE 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 engine 8 Start the engine and allow it to run for five minutes then shut the engine off and allow it to cool 9 Repeat steps 7 8 at least two more tim...

Page 179: ...wn verifying it has returned to the fully closed position Cooling System Schematics The following schematics are representative of the differ ent styles of cooling systems in the Arctic Cat snowmo biles Some components may vary from model to model therefore the technician should use discretion and sound judgment when servicing a particular cooling system 0744 065 0744 064 0746 354 0746 522 CAUTION...

Page 180: ...3 18 0742 314 0746 520 F5 LXR 800 cc ...

Page 181: ...ashers and pawl for wear or damage 3 Inspect the roller and case for cracks or damage 4 Inspect the center hub for wear cracks or damage 5 Inspect the rope for breaks or fraying 6 Inspect the main spring for cracks crystallization or abnormal bends 7 Inspect the handle for damage cracks or deteriora tion ASSEMBLING 1 Hook the end of the main spring around the mount ing lug in the case 2 Insert the...

Page 182: ...e and account for the handle cap then thread the rope through the bushing in the console 3 Remove the cap screws A securing the starter assembly to the magneto case then remove the starter assembly DISASSEMBLING 1 Secure the recoil starter in a vise 2 Rotate the roller B counterclockwise until the notch of the roller is near the rope guide in the case Guide the rope into the notch and slowly allow...

Page 183: ...rease 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 the friction plate into position allowing it to rest on the friction plate spring then install the cap screw cap screw w washer coated with blue Loctite 243 and thread the cap screw in until it contacts the friction plate 11 Pr...

Page 184: ...panel will remain secured to the chassis 7 Remove the cap screw located directly above the ECU securing the air silencer duct to the front upper panel then disconnect the air temperature sensor and remove the duct NOTE To aid in accessing the cap screw the ECU may be removed 8 Remove the body screws and flange nuts C from each side securing the front bumper assembly to the chassis then remove the ...

Page 185: ...screws securely then con nect the harness plug ins to the ECU FS202A 6 Using the illustration following step 2 secure the left side rear spar panel to the gas tank and support tube with the three torx head screws D Tighten the screws securely 7 Install the 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 bumpe...

Page 186: ...e support back out of the way ZJ010A 7 Disconnect the fuel pump four wire connector then slide the gas tank rearward enough to gain access to the gasline hose connector ZJ011A 8 Compress the clip on the gasline hose connector and remove the hose from the gas tank then disconnect the vent hose and remove the gas tank IO053A NOTE After the gas tank vent hose has been removed plug the hose outlet of ...

Page 187: ... seven machine screws and separate the air silencer halves 16 Inspect the air silencer thoroughly for any foreign material then clean the air silencer with soap and water Dry the air silencer thoroughly prior to install ing INSTALLING 1 Join the air silencer halves and secure with the seven machine screws then install the dual intake boot and secure with retaining clips 2 Install the air temperatu...

Page 188: ...TE Before placing the gas tank into position on the chassis install the gasline hose to the tank push down on the connector until it snaps into place and route the vent hose to its proper position as noted during removing IO054A 5 Install the gas tank to its proper position then secure the gas tank with the seat support assembly and install the six torx head cap screws Tighten securely ZJ010A 6 In...

Page 189: ... install both access panels Air Silencer 1100 cc Turbo REMOVING INSPECTING 1 Remove the air cleaner cover then remove the air filter 2 Inspect the filter for tears or dirt and replace if neces sary Clean any debris from inside the air intake ple num INSTALLING Place the air filter into position into the plenum then secure the air cleaner cover onto the plenum Turbocharger Intercooler F XF M 1100 c...

Page 190: ...wo cap screws and nuts securing shock mount support bracket Remove the rear heat shield front spar and shock mount SNO 232A NOTE To aid in the removal of the assembly from step 6 drill out the rivet A securing the rear heat shield to the left spar tube 8 Remove the banjo bolts with four crush washers securing the oil feed pipe to the turbocharger and to the engine Discard the washers CAUTION Do no...

Page 191: ...Remove the cap screws securing the lower heat shield to the exhaust manifold and turbocharger then remove the mounting bracket 13 Remove the lock nuts securing the turbocharger out let then remove the turbocharger outlet from the tur bocharger and account for the gasket 14 Remove the four lock nuts securing the turbocharger to the exhaust manifold Account for the gasket and flat washers INSPECTING...

Page 192: ...the three lock nuts securing the turbocharger mounting bracket to the engine Tighten the nuts to 30 ft lb and bend each tab to secure the nut PC234A 7 Tighten the two lock nuts from step 2 to 30 ft lb 8 Using a crisscross pattern tighten the lock nuts from step 3 securing the turbocharger to the exhaust manifold to 30 ft lb 9 Connect the coolant feed hose and oil return hose to the turbo release t...

Page 193: ...n sensor then install the cap screws nuts new gasket and spring securing the resonator to the chassis PC227 NOTE Check the coolant level and the oil level Add as necessary see Section 4 18 Install the right and left side panels then install the hood Turbocharger Intercooler T Series 1100 cc Turbo WARNING The rotating components in a turbocharger turn at speeds of 150 000 RPM Any imbalance could ca...

Page 194: ...arger inlet TZ058A 7 Using a suitable clamping device clamp off the cool ant return hose then remove 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 turbocharger outlet and exhaust mani fold TZ061 9 Loosen the hose clamp and remove the waste gate control valve hose from the ...

Page 195: ...E If the oil hose has to be removed from the engine note the banjo bolt securing the hose to the turbocharger has the smaller feed holes 743 780C 13 Remove the lock nuts and washers securing the exhaust manifold to the engine cylinder head then carefully remove the turbocharger and exhaust mani fold assembly TZ089 14 Remove the cap screws securing the lower heat shield to the exhaust manifold and ...

Page 196: ...With the turbocharger secured in a suitable vise and the gasket in place secure the turbocharger outlet to the turbocharger with the washers and lock nuts Tighten the lock nuts to 30 ft lb TZ091A 2 Install the mounting bracket to the turbocharger then with the backing plate properly positioned as noted during disassembling secure the bracket to the tur bocharger with the lock nuts and tighten only...

Page 197: ...securing the turbocharger to the exhaust manifold to 30 ft lb TZ092A 8 Connect the coolant feed hose and oil return hose to the turbo release the clamps and secure the hoses with the hose clamps 743 991A 9 With the turbocharger secured connect the top oil feed pipe with the banjo bolt and two new crush washers Tighten to 11 ft lb TZ062A 10 Install the exhaust pipe and secure with the five exhaust ...

Page 198: ...coolant is required bleed the cool ing system see appropriate Liquid Cooling System in this section Arctic Power Valve APV System 800 cc The Arctic Power Valve APV System adjusts the size of the exhaust ports to produce maximum horsepower on the top end while providing excellent low end power and increased touring fuel economy THEORY Two cycle engines and their exhaust systems are designed to prod...

Page 199: ...OPERATION At idle and low speed operation the exhaust valves are held in the low port position by the return spring When engine RPM reaches a predetermined point the ECU will send a signal to the servo which cycles and pulls the exhaust valves into the up or high port position If the servomotor cycles the exhaust valves as explained above the exhaust valve circuit is operating satisfacto rily If t...

Page 200: ...e 4 While holding the cable housing lightly pull on one cable end to remove any slack then measure the amount of exposed cable from the cable housing to the end of the cable NOTE The two cable measurements must be equal in length or less than 0 5 mm 0 020 in difference in length from each other NOTE Repeat steps 3 and 4 for each cable then compare the measurements to the APV Cable Length chart in ...

Page 201: ... from the valve stopper FC113 Cleaning and Inspecting 1 Remove all carbon deposits with solvent 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 damage the valve plate FC116 2 Install the new seal using an appropriate sized seal driving tool FC117 ASSEMBLI...

Page 202: ...sition on the engine Secure with two cap screws Tighten to 96 in lb FC023 6 Perform steps 5 8 in Cable Adjustment in this sub section TROUBLESHOOTING The APV system has a self testing mode built in Every time that the engine is started the servo will cycle once The ECU monitors the voltages at the servo during this cycle to assure they are within operational tolerances If all voltages are within t...

Page 203: ...iming accordingly This system is not adjustable and is maintenance free If a system fault is suspected use an ohmmeter to check continuity of the exhaust pipe temperature sensor located in the expansion chamber A reading of either 0 ohm or infinity indicates a failed sensor 0737 314 NOTE A disabled ECT system WILL NOT cause engine damage however a failed ECT system will have slower throttle respon...

Page 204: ...3 42 NOTES ...

Page 205: ...e Cable 4 11 Fuel Pump 4 11 Troubleshooting 4 12 Fuel System EFI 4 13 Individual Components 4 13 Self Diagnostic System Codes 4 16 Fuel Pressure Regulator 4 17 Throttle Body Assembly 4 17 Throttle Cable 4 22 Fuel Filter 1100 cc 4 22 Fuel Pump F M XF 4 23 Fuel Pump Bearcat F Series T Series 4 25 Troubleshooting 4 26 Oil Injection Pump 4 27 Gas Tank 4 29 ...

Page 206: ...ose must fit tightly at both ends If loose or cracked replace the hose 5 Check each carburetor vent hose for kinks or obstructions remove any obstructions 6 Check each carburetor float chamber drain hose for water or debris If seen clean by removing the plug and draining the drain hose into a small container 7 Check the gas tank vent hose and fuel hose for obstructions remove any obstructions Chan...

Page 207: ...using from the carburetor TZ103A TZ104A 4 Loosen the carburetor flange clamp then remove the carburetor TZ102A NOTE Slide the carburetor into the air silencer boot until free of the flange then remove carburetor 5 Remove the clamp and disconnect the fuel hose from the carburetor inlet fitting then loosen the lock plate screw and remove the lock plate from the missing body top AH284D 6 Remove the m...

Page 208: ...ain jet and baffle ring then remove the main jet extender guide from the needle jet Push the needle jet out through the top of the carburetor KEY 1 Mixing Body Assy 2 Starter Plunger Cap 3 Starter Plunger Spring 4 Starter Plunger 5 Spring 6 Idle Speed Screw 7 Spring 8 Pilot Air Screw 9 Pilot Jet 10 Baffle Ring 11 Main Jet 12 Mixing Body Top 13 Piston Valve Spring 14 Plate 15 Magnet Block 16 Screw ...

Page 209: ...ble by compressing the spring and removing the plunger from the cable then remove the spring Thread the plunger cap off the cable CLEANING 1 Place all metallic components in a wire basket and submerge in carburetor cleaner 2 Soak for approximately 30 minutes then rinse with fresh parts cleaning solvent 3 Wash all non metallic components with soap and water Rinse thoroughly CAUTION If an engine pro...

Page 210: ...mage 9 Inspect the carburetor mounting flanges for damage and tightness ASSEMBLING 1 Install the idle speed screw and spring CM053B 2 Install the pilot air screw and spring Rotate clock wise until lightly seated then turn counterclockwise the same number of turns as noted in disassembling for an initial setting CM053A 3 Install the pilot jet CM052 4 Insert the needle jet into position from the top...

Page 211: ...et and float chamber into position and secure with the four screws and lock washers making sure the hose plates are properly positioned on the two front screws Install the vent hoses AH137 10 Place the E clip into position on the jet needle From the bottom of the jet needle slide the E clip washer up against the E clip Place the jet needle into the piston valve NOTE Place the E clip in the proper ...

Page 212: ...mp mak ing sure the carburetor is level Do not over tighten the flange clamp as it will damage the carburetor flange TZ102A NOTE Slide the carburetor into the air silencer boot then slide the carburetor into the flange 5 Thread the brass choke cable housing into the carbu retor making sure the washer is properly positioned and tighten securely TZ104A 6 Connect the safety switch harness connectors ...

Page 213: ...le lever to the full open position then rotate each idle speed screw clockwise 2 com plete turns Release the throttle lever NOTE The throttle control is equipped with a 3 prong emergency stop switch connector There must be free play between the lever and the control housing 741 518A NOTE If cable free play gap is not correct rotate each swivel adapter an equal amount until recom mended free play i...

Page 214: ...PM reading The piston valves should now be synchronized and the engine should idle without holding any throttle pres sure NOTE If the engine has no ignition spark with the throttle in the idle position but has proper spark with the throttle lever slightly compressed the carburetor safety switches must be repositioned 5 Test the throttle control lever by compressing and releasing it several times T...

Page 215: ...nsole 725 001A 6 Slide the choke lever housing from the console 7 Cut any cable ties used to secure the choke cable and remove the choke cable from the engine compartment INSTALLING 1 Position the choke lever in the middle choke posi tion then from the back side of the console insert the choke lever housing through the console Secure with the knurled nut 2 Route the choke cable from the console to...

Page 216: ...needle jet replace adjust jet needle E clip Problem Carburetor Too Lean 0 1 4 Opening Condition Remedy 1 Choke plunger remains seated 2 Pilot air screw too far out damaged 3 Piston valve sticks open damaged worn 4 Pilot jet outlet obstructed 5 Float inlet needle obstructed damaged adjusted incorrectly 1 Adjust service choke cable plunger assembly 2 Adjust replace pilot air screw 3 Service replace ...

Page 217: ...ch condition and will greatly reduce performance However the engine will be pro tected from a possible lean condition and engine damage The ECU is equipped with a self diagnostic system uti lizing the service icon in the speedometer tachometer and remains illuminated when a problem exists with any of the sensors The technician can determine the problem sensor by reading the code shown on the reado...

Page 218: ...he coolant temp rises above 105 C 221 F 4 Stroke the temp light on the gauge will start to flash and the engine will go into a fuel cut surging mode to alert the rider of overheating If the temp continues to rise and exceeds 110 C 230 F the temp light will be on continu ously The fuel cut will not protect the engine from over heating if the operator continues to ride the snowmobile THROTTLE POSITI...

Page 219: ...t be properly functioning Check the following components before considering the fuel pump assembly to be defective A Fuel pump coil see coil test procedure B Emergency stop switch and ignition switch must be ON C Fuel pump see fuel pump test procedure D Wiring harness and connectors clean the connec tors and test the harness E ECU CRANKSHAFT POSITION SENSOR 1100 cc This sensor measures the locatio...

Page 220: ...is played on the readout screen the ECU is receiving input that is outside of its established parameters Refer to the appropriate ECU Diagnostic Codes chart FZ001D FZ003B 800 cc only NOTE For codes ECU 16 and ECU 18 see Servomo tor Potentiometer Test in Section 5 For CCU codes see Section 5 Turbo only Deluxe Gauge ECU Diagnostic Codes 2 Stroke Code Trouble 2 Failure in injector s 4 Open or short c...

Page 221: ...es then loosen the jam nut securing the throttle cable and remove 7 Remove the throttle body assembly INSTALLING 500 800 cc 1 Attach the throttle cable to the throttle body then secure with jam nut Secure the coolant hoses to throttle body assembly 2 Place the throttle body assembly into position Make sure the flanges and boots are positioned properly Secure with flange clamps 3 Where applicable c...

Page 222: ...from the throttle body assembly ZJ290 NOTE For assembling purposes note from which side the fuel injectors were removed ASSEMBLING INSTALLING 1100 cc Non Turbo 1 Install the fuel injectors onto the throttle body assem bly then secure the fuel rail and injectors to the throttle body assembly with the two screws and the retaining clips ZJ291A ZJ290 2 Install the throttle body assembly to the intake ...

Page 223: ...ort tube 4 Remove the screws D and E securing the left front spar panel to the front bumper then remove the spar panel Remove the seat see Section 8 5 Disconnect the throttle cable A then disconnect the idle speed control B TZ108A 6 Remove the harness connector from the throttle posi tion sensor A then place a towel under the throttle body coolant hoses B and with a suitable clamping device close ...

Page 224: ...p screws securing the fuel rail injectors to the intake flange TZ111A NOTE After removing the fuel rail account for the four injector gaskets 13 Remove the four harness connectors from the injec tors then carefully remove the injectors from the fuel rail TZ113 NOTE With the injectors removed inspect the O rings and gaskets for damage TZ113A 14 If necessary remove the cap screws securing the fuel p...

Page 225: ...ly TZ110A 5 With a new throttle body gasket secure the throttle body with the cable support bracket to the intake ple num with the four caps screws then tighten to 18 ft lb TZ109A 6 Install the hose connecting the intake pipe to the throttle body and secure with the hose clamps 7 Install the coolant hoses to the throttle body and secure with the clamps then install the harness con nector to the th...

Page 226: ...g sure the cable snaps into place 2 Install the throttle cable end on the throttle lever 3 Route the throttle cable from the throttle control assem bly to the throttle body assembly and oil injection pump avoid any sharp bends or moving components 4 Attach the throttle cable to the pulley on the throttle body shaft 5 On the 500 cc install the oil injection cable adjuster on the oil injection pump ...

Page 227: ...Bearcat T Series 1 Open the left side access panel then remove the fuel filter from the bracket ZJ135B TZ118A 2 Remove the hose clamps and discard then slowly remove the gasline hoses from the fuel filter Dispose of the excess fuel from the filter properly NOTE Inspect the fuel lines thoroughly for any signs of cracking cuts or wear points INSTALLING Bearcat T Series 1 Place new hose clamps on the...

Page 228: ...lack release and finally pulling back on the hose SNO 684A 3 Remove and retain the six torx head screws securing the fuel pump in the fuel tank then remove the retaining ring 4 Carefully remove the fuel pump and fuel pickup assembly from the gas tank noting the orientation of the fuel pump outlet for assembling purposes SNO 702 NOTE If the fuel pickup assembly is not being replaced inspect the scr...

Page 229: ...ith no kinks in the fuel hose SNO 706 5 Install the retaining ring over the fuel pump and secure the fuel pump to the gas tank assembly using the existing torx head screws Tighten to 40 in lb 6 Connect the fuel pump harness connector to the main harness and secure to the retaining ring with a cable tie then secure the gasline hose to the fuel pump making sure it locks into place 7 Install the uppe...

Page 230: ... then with a new hose clamp secure the gasline hose with the pickup assembly to the inlet of the fuel pump 2 Install the fuel pump and pickups into the gas tank and position the fuel pump so the outlet is properly oriented as noted during removing 3 Install the retaining plate and secure to the gas tank with the six self tapping screws Tighten to 40 in lb 4 Install the gas tank see Gas Tank in thi...

Page 231: ...a washer gas ket check valve and washer gasket then install on the oil injection pump 2 Place the gasket and oil injection pump near the engine then install the lower union bolt through a gasket check valve and gasket 3 Position the oil injection pump on the engine making sure the oil injection pump gear is correctly aligned with the oil injection pump drive gear 4 Secure the pump with two screws ...

Page 232: ...and placing the rubber strap around the tool and the oil reservoir filler neck NOTE On the F570 the tool can be secured to the air silencer NOTE On the F M XF to access the oil pump the air intake boot must be removed NOTE On the 800 cc the control rod must be secured in the Idle position Secure the rod away from any moving parts to prevent misalignment of the control rod due to engine chassis mov...

Page 233: ...isconnect the reverse alarm then remove the two machine screws A securing the upper console Remove the console SNO 680A 4 Remove and retain all four cap screws A securing the rear spar tubes to the chassis and steering support SNO 681A SNO 682A 5 Disconnect the gasline hose vent hose and fuel pump harness Remove the gas tank SNO 684 INSTALLING F M XF 1 Install the gas tank then connect the gasline...

Page 234: ...l the gas tank to its proper position then secure the tank with the seat support assembly and install the four cap screws securing the seat support tubes to the support plate Tighten securely NOTE It may be necessary to align the U nut clips with a punch 3 Install the six torx head screws securing the seat sup port assembly to the tunnel 4 Connect the fuel pump four wire connector FS261A 5 Install...

Page 235: ... 5 18 Magneto 4 Stroke 5 18 Ignition Timing 2 Stroke 5 21 Brakelight Switch 5 21 Headlight Dimmer Switch 5 21 Testing Handlebar Warmer Elements 5 22 Testing Thumb Warmer Element 5 22 Testing Handlebar Warmer Thumb Warmer Switch 5 22 Testing Passenger Handwarmer Switch 5 23 Testing Passenger Handwarmer Elements 5 23 Testing Seat Heater Harness Switches 5 23 Testing Speedometer Sensor 5 24 Testing G...

Page 236: ...adjust the throttle cable tension 3 On the 570 cc if no spark is present disconnect the main wiring harness 4 pin connector from the engine Crank the engine over If spark is present the problem is either one or more of A D below 4 On the 4 stroke if no spark is present the problem is either one or more of A D below A Defective emergency stop switch B Defective safety switch in throttle control hou...

Page 237: ...ify the idle speed screws are adjusted equally and the pis ton valves are synchronized The carburetor safety switches affect ignition spark at idle only If ignition spark problems are observed at partial or full throttle positions the problem is not with the carburetor safety switches 1 Inspect the cable free play gap between the throttle lever and the control housing at idle Adjust the throttle c...

Page 238: ... the digital volt meter into the red jack of the adjustment tool and the black lead of the digital voltmeter into the black jack of the adjustment tool The green power light of the ana lyzer should now be illuminated If voltage is found below 4 9 volts replace the battery NOTE The Test Harness must be plugged into the analyzer for testing voltage Always verify battery voltage is at least 4 9 DC vo...

Page 239: ...ft stop Using the digital multimeter and test harness rotate the idle screw inward until the Idle specification is observed NOTE Rotate the idle screw past the recommended voltage specification by two or three volts then rotate the idle screw counterclockwise to the correct idle position voltage 7 With the idle position set to specification slowly compress the throttle lever to the full open posit...

Page 240: ... if the reading remains within the specification NOTE If after adjusting the Throttle Position Sen sor to the IDLE specification the FULL OPEN is less than 4 30 volts recheck the IDLE setting If the IDLE setting is correct replace the sensor REPLACING TPS 1100 cc NOTE Replacing the TPS is for out of warranty snowmobiles only Removing NOTE On the F M XF non turbo remove the hood seat see Section 8 ...

Page 241: ... be 1 52 2 28 ohms Injection Coil 1 Test between the two blue white leads in the connec tor harness from the stator plate 2 Resistance must be 15 2 22 8 ohms Lighting Coil 1 Disconnect the three wire connector from the mag neto 2 Connect the two meter leads to each of the yellow leads in the connector from the lighting coil 3 Resistance must be 0 08 0 12 ohm Ignition Timing Sensor 1 Disconnect the...

Page 242: ...ector 2 Connect the two meter leads to each of the yellow leads in the connector from the engine 3 Resistance must be 0 12 0 18 ohm Ignition Coil Primary 1 Disconnect the double wire plug from the CDI unit to the ignition coil 2 Connect the red meter lead to the orange wire in the plug then connect the black meter lead to the black white wire in the plug 3 Resistance must be 0 26 0 35 ohm Ignition...

Page 243: ...gnition switch terminals 4 Rotate the key to the RUN position The meter must read OL infinite resistance Fuel Injector 1 Disconnect the fuel injector wiring harness then set the meter to the OHMS position 2 Test between the two injector terminals Resistance must be 10 14 ohms 3 If not within specifications replace the injector Exhaust Temperature Sensor 1 Disconnect the sensor harness then remove ...

Page 244: ...CU Tests NOTE The following test should be made using MaxiClips and the Fluke Model 77 Multimeter set to DC Volt scale This test should be made at the three pin connector of the regulator rectifier 500 cc 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 lead of the con nector 2 Start the engine and allow it ...

Page 245: ...01D Accessing CCU Codes 1 Connect the appropriate harness from CCU Diagnos tic Test Kit to the diagnostic port 2 Start the engine After approximately 5 seconds the service icon on the gauge will begin flashing 3 The readout screen will display an error code as CCU followed by a number refer to the CCU Diag nostic Codes chart for descriptions When all error codes have been output the service icon f...

Page 246: ... Disconnect the fuel gauge sender unit from the main wiring harness then connect the ohmmeter leads to the two blue sender wires 3 Compare the reading to the chart following Emergency Stop Switch RESISTANCE 1 Remove the four torx head cap screws securing the front rear throttle control housing assembly to the handlebar 2 Set the selector to the OHMS position 3 Connect one tester lead to one pin th...

Page 247: ...tch TESTING 1 Disconnect the wiring harness from the ignition switch then remove the switch from the console 2 Using the ohmmeter test the connections indicated in the following charts If the meter reads more than one ohm of resistance between connected terminals or less than 1 ohm of resistance on non connected terminals the switch must be replaced 746 238A 746 246A NOTE If the ignition switch te...

Page 248: ... spring ASSEMBLING PINION 1 Slide the pinion gear spring retainer pinion spring and snap ring retainer note end for end orientation onto the shaft in their original positions 2 Place new snap ring over the end of the pinion shaft then slide the snap ring over the shaft Using a 11 mm or 7 16 in socket and a hammer gently tap the snap ring into the groove on the shaft 3 Slide the dust cover over the...

Page 249: ...ries remove the air silencer see appropriate Air Silencer sub section in Section 3 then remove the positive cable from the battery 2 On the F M XF remove the driven pulley seat gas tank throttle bodies and intake flange then remove the cap screw securing the upper portion of the left rear engine mount to the engine PC254A 3 On the F M XF carefully pry on the engine enough to remove the starter mot...

Page 250: ...oves Carefully remove any buildup by undercutting using a thinly ground hack saw blade Do not cut any deeper than the original groove which can be seen by looking at the end of the commutator 9 Using a caliper 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 po...

Page 251: ...the armature 2 Install the armature into the brush assembly then using a small needle nose pliers carefully move the brush wires upward allowing the brushes to fully contact the commutator ZJ145 NOTE After completing step 2 ensure that the brushes are properly seated to the commutator 3 Noting the alignment marks made in disassembling install the magnet housing then with the magnet housing properl...

Page 252: ...Troubleshooting Electric Start Magneto 4 Stroke REMOVING NOTE Prior to removing the magneto the engine oil and cooling system must be drained see Section 3 1 Disconnect the connector for the exhaust tempera ture sensor then remove the cap screws nuts and springs securing the and resonator 2 On the F M XF remove the cap screws and nuts securing the MAG side chassis support then remove all clamps an...

Page 253: ...o the engine then remove the cover and account for the dowel pins the oil pump seal and the gasket ZJ147 7 Remove the cap screws securing the harness clamp and timing sensor to the magneto cover ZJ148A 8 Remove the three cap screws securing the magneto to the cover then remove the magneto assembly ZJ149A 9 Remove the torque limiter idler gear assembly from the magneto cover For installing purposes...

Page 254: ...ump oil cooler and separator tank then secure the hoses with the clamps NOTE Steps 5 6 are for the Bearcat T Series only 5 Place the oil tank into position in the chassis and install the breather hose then secure with the clamp With the hoses routed properly install the supply return oil hoses to the tank then secure the hoses with new clamps NOTE Assure the O rings are properly seated in the supp...

Page 255: ... read OL open If the meter does not read as specified the brakelight switch is defective and must be replaced 4 To remove the switch remove the snap ring then remove the pin securing the brake lever to the control assembly 5 Using a small flat blade screwdriver compress the tabs of the switch then push the switch toward the end of the handlebar and out of the control assembly CM108A INSTALLING 1 S...

Page 256: ...than or more than the specified amount NOTE Repeat test for the other element 7 Connect the leads then install the handlebar control assembly and secure the handlebar pad if applica ble Testing Thumb Warmer Element NOTE Resistance will vary due to temperature therefore this test should be made at room tempera ture of 20 C 68 F 1 Remove the handlebar pad if applicable then dis connect the thumb war...

Page 257: ...te wire from the element then connect the other ohmmeter lead to the green wire from the element The meter must read between 23 8 32 2 ohms 3 For the HI position connect one ohmmeter lead to the green blue wire from the element then connect the other ohmmeter lead to the green wire from the ele ment The meter must read between 8 7 11 7 ohms Testing Seat Heater Harness Switches NOTE The seat heater...

Page 258: ... T Series remove the six torx head cap screws securing the left side footrest to the chassis and remove the footrest then un thread the switch from the gear case 2 Disconnect the switch two wire connector 3 Connect one ohmmeter lead to one black wire then connect the other ohmmeter lead to the other black wire 4 With the reverse button pressed in the meter must read less than 1 ohm of resistance W...

Page 259: ...d terminal Note the direction of rotation 4 Reverse the connections on the servo terminals pos itive lead to black red and negative lead to red black The servomotor should rotate in the opposite direc tion 5 Install the servomotor NOTE If the servo operates correctly in the above test but fails to operate when connected to the ECU CCU regulator rectifier at the designated RPM pro ceed to Potentiom...

Page 260: ...5 26 Troubleshooting Servomotor SERVO1A12 ...

Page 261: ...5 5 27 SERVO2rv ...

Page 262: ...2 C 90 F 1 072 7035 40 C 40 F 4 729 425000 30 C 86 F 1 139 7550 Temperature Volts Ohms Temperature Volts Ohms 110 C 230 F 0 115 129 28 C 82 F 1 377 1800 108 C 226 F 0 129 137 26 C 79 F 1 459 1950 106 C 223 F 0 143 145 24 C 75 F 1 541 2100 104 C 219 F 0 157 153 22 C 72 F 1 623 2250 102 C 216 F 0 171 161 20 C 68 F 1 705 2400 100 C 212 F 0 185 169 18 C 64 F 1 806 2670 98 C 208 F 0 192 180 16 C 61 F 1...

Page 263: ...p 1 passenger seat harness on p 22 and miscellaneous Groomer Special harnesses on p 29 Model Ignition Main Harness Hood Console Harness Handlebar Harness Bearcat 570 F570 T570 p 2 p 15 p 24 Bearcat Z1 XT GS LTD p 9 p 19 p 21 F 800 M 800 XF 800 p 6 p 14 p 23 F5 LXR p 3 p 16 p 25 F 1100 M 1100 XF 1100 p 4 p 17 p 26 F 1100 Turbo M 1100 Turbo XF 1100 Turbo p 5 p 17 p 26 M 1100 Turbo Sno Pro HCR p 5 p ...

Page 264: ...Magneto 0746 255 1 ...

Page 265: ...Main Harness p n 1686 600 F570 p n 1686 601 Bearcat 570 T570 p n 1686 612 Bearcat 570 XT 0746 237 2 ...

Page 266: ...Main Harness p n 1686 603 F5 LXR 0746 249 3 ...

Page 267: ...Main Harness p n 1686 624 F 1100 Sno Pro M 1100 Sno Pro XF 1100 Sno Pro p n 1686 625 F 1100 LXR LTD Ann M 1100 Sno Pro LTD Ann XF 1100 LXR LTD Ann 0746 248 4 ...

Page 268: ...R Sno Pro LTD Ann M 1100 Turbo Sno Pro LTD Ann XF 1100 Turbo LXR XF 1100 Turbo Sno Pro LTD Ann p n 1686 623 F 1100 Turbo Sno Pro M 1100 Turbo Sno Pro HCR M 1100 Turbo 153 Sno Pro 162 XF 1100 Turbo High Country XF 1100 Turbo Sno Pro 0746 245 5 ...

Page 269: ...Main Harness p n 1686 588 F 800 M 800 XF 800 0746 242 6 ...

Page 270: ...Main Harness p n 1686 611 TZ1 Turbo LXR LTD 0746 253 7 ...

Page 271: ...Main Harness p n 1686 610 TZ1 TZ1 LXR 0746 252 8 ...

Page 272: ...Main Harness p n 1686 613 Bearcat Z1 XT GS p n 1686 615 Bearcat Z1 XT LTD 0746 511 9 ...

Page 273: ...Main Harness p n 1686 578 Sno Pro 120 10 0744 204 ...

Page 274: ...Ignition Main Harness p n 1686 628 Sno Pro 500 11 0745 605 ...

Page 275: ...Ignition Main Harness p n 1686 657 Sno Pro 600 12 0746 250 ...

Page 276: ...0745 601 13 Console Harness p n 1686 631 TZ1 LXR TZ1 Turbo LXR LTD ...

Page 277: ...Hood Harness p n 1686 638 F 800 M 800 XF 800 0746 243 14 ...

Page 278: ...Console Harness p n 1686 633 Bearcat 570 F570 T570 0746 238 15 ...

Page 279: ...Console Harness p n 1686 634 F5 LXR 0746 240 16 ...

Page 280: ...Hood Harness p n 1686 639 F 1100 Turbo M 1100 Turbo HCR XF 1100 Turbo 0746 246 17 ...

Page 281: ...Hood Harness p n 1686 658 Sno Pro 600 Cross Country p n 1686 664 Sno Pro 600 Sno Cross 18 0746 251 ...

Page 282: ...0746 254 19 Console Harness p n 1686 547 Bearcat Z1 XT GS p n 1686 549 Bearcat Z1 XT LTD TZ1 ...

Page 283: ...Hood Harness p n 1686 587 Sno Pro 500 20 0744 201 ...

Page 284: ...Handlebar Harness p n 1686 652 TZ1 LXR Turbo LXR LTD p n 1686 653 Bearcat Z1 XT GS LTD 0746 513 21 ...

Page 285: ...Passenger Seat Harness p n 1686 570 22 0744 197 ...

Page 286: ...Handlebar Harness p n 1686 636 F 800 M 800 XF 800 p n 1686 654 M 800 HCR 0746 244 23 ...

Page 287: ...Handlebar Harness p n 1686 537 Bearcat 570 F570 T570 0746 239 24 ...

Page 288: ...Handlebar Harness p n 1686 574 F5 LXR 0744 189 25 ...

Page 289: ...Handlebar Harness p n 1686 637 F 1100 Turbo M 1100 Turbo XF 1100 Turbo 0746 247 26 ...

Page 290: ...Handlebar Harness p n 1686 590 Sno Pro 500 27 0744 200 ...

Page 291: ...Handlebar Harness p n 1686 656 M 1100 Turbo Sno Pro HCR 28 0746 510 ...

Page 292: ...Misc Groomer Special p n 1686 645 p n 1686 646 p n 1686 647 p n 1686 648 29 0746 241 ...

Page 293: ... F M XF 6 9 Drive Clutch Driven Pulley 6 12 Drive Train Bearcat F Series T Series 6 13 Drive Train F M XF 800 6 25 Drive Train F M XF 1100 6 29 Drive Sprockets 6 37 Track Tension 6 40 Track Alignment 6 41 Brake System Hydraulic 6 42 Brake Lever Master Cylinder Assembly 6 55 Troubleshooting Track 6 56 Troubleshooting Hydraulic Brake System 6 57 Troubleshooting Drive Clutch Driven Pulley 6 58 ...

Page 294: ...he adjuster NOTE Assure that the shims and O ring are not removed from the adjuster 0743 395 3 On 500 570 and 1100 cc reverse the adjuster and install the cap screw without washers into the adjuster Install the sheave adjuster and cap screw onto the driven pulley then tighten the cap screw until the movable sheave opens far enough to allow the belt to be removed 4 On 800 cc models remove the adjus...

Page 295: ...bling the drive clutch for balance purposes NOTE If equipped with a fan remove the three cap screws securing the fan to the clutch XM008A 1 Loosen the machine screws securing the cover Remove every other cap screw and lock washer from the cover then while firmly holding the cover remove the three remaining screws and lock washers equally 2 Remove the cover and spring FC055 3 Remove the cam arm pin...

Page 296: ...nstalling NOTE Before installing the drive clutch be sure to wipe both the crankshaft taper and clutch mounting taper clean using a clean towel 1 Place the drive clutch into position on the crankshaft then apply a few drops of oil to the threads of the cap screw Secure with the cap screw and lock washer Tighten to 51 ft lb 2 Check alignment between the drive clutch and driven pulley see Drive Clut...

Page 297: ...ol then install the compressor flange spacer and wing nut and compress the driven pulley spring FS090 3 Remove the torx head cap screws securing the mov able sheave to the torque bracket CM061 NOTE To loosen the torx head cap screws it may be necessary to insert a torx bit and strike each screw with a hammer 4 Release the compression of the spring by removing the wing nut then remove the movable s...

Page 298: ... Clearance between the shaft and the respective bearing must not exceed 0 020 in If the clearance exceeds the specification the driven pulley must be replaced NOTE The movable sheave bearing is a non ser viceable component CM101 FS122 FS123 REPLACING TORQUE BRACKET BEARING COVER BEARING 1 Remove the snap ring 2 Using a suitable driving tool drive the bearing out 3 Install the new bearing then secu...

Page 299: ...BLING 1 Place the torque bracket onto the Driven Pulley Compressor Tool then install the spring seats onto the torque bracket and place the spring into position CM064 CM063 NOTE Premature wear will result 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 onto...

Page 300: ...compress the driven pulley spring CM069 6 Install the torx head cap screws securing the movable sheave Tighten in a crisscross pattern to 72 in lb CM061 7 Remove the pulley from the compressor INSTALLING 1 Set the brake lever lock 2 Install the alignment washers then install the driven pulley onto the input shaft CM125A 3 Check drive clutch driven pulley alignment then install the drive belt see D...

Page 301: ...ange spacer and wing nut and compress the driven pulley spring PC109 2 Remove the torx head screws A securing the back side cams then remove the cap screws B securing the movable sheave to the torque bracket PC110A NOTE To loosen the cap screws it may be neces sary to heat the heads with a torch to soften the Loc tite 3 Release the compression of the spring by removing the wing nut then remove the...

Page 302: ...ring must not exceed 0 020 in If the clearance exceeds the specification the driven pulley must be replaced PC115A PC117A PC111A REPLACING TORQUE BRACKET BEARING COVER BEARING 1 Remove the snap ring 2 Using a suitable driving tool drive the bearing out 3 Install the new bearing then secure with the snap ring REPLACING ROLLERS 1 Bend the locking tabs down away from the shoulder bolt then remove the...

Page 303: ...ary sheave spring seat onto the spring flat side toward the spring then noting the alignment marks made during disassembling place the stationary sheave onto the torque bracket PC126 3 Place the movable sheave onto the stationary sheave 4 With the pulley in place on the compressor install the compressor flange spacer and wing nut then compress the driven pulley spring PC109 5 With a drop of red Lo...

Page 304: ...d rest on the stationary shaft at point C If the bar either will not clear the inside edge or is more than the specified amount the offset must be corrected 0744 549 CORRECTING OFFSET 1 To correct offset the driven pulley must be moved laterally on the input shaft Remove the cap screw and washers securing the driven pulley NOTE If the driven pulley is tight on the shaft pull the driven pulley off ...

Page 305: ...t lb from step 5 7 Install drive belt see Drive Belt in this section 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 following procedure NOTE Make sure the drive belt is sitting at the top of the driven pulley sheaves 1 Place a straightedge on top of the drive belt The straightedge should rea...

Page 306: ...ner driveshaft securing the driveshaft to the gear case 742 020A NOTE If the gear case is being removed do not remove the 5 8 in cap screw If only the track drive shaft is being removed remove the cap screw and proceed to step 10 6 Remove the lock nuts securing the gear case to the chassis then remove the remaining lock nut A from the torx head cap screw 742 195E NOTE On the Bearcat Z1 TZ1 after c...

Page 307: ...move the skid frame Account for lock washers and flat washers 14 On the Bearcat remove all four cap screws and lock nuts if applicable then remove the skid frame 15 With the gear case and skid frame removed pull the driveshaft toward the gear case side of the tunnel until it clears the brake caliper housing then remove the driveshaft Account for the rubber seal ZJ212 NOTE The brake disc can remain...

Page 308: ...cers then secure with the two cap screws Tighten to 17 ft lb NOTE At this point install and secure the battery then connect the battery cables positive cable first 6 If the gear case is installed secure the driveshaft to the output shaft with the cap screw coated with blue Loctite 243 and washer Tighten to 70 ft lb 742 020A NOTE If the gear case is not installed do not secure the driveshaft to the...

Page 309: ...w A from the back side of the chassis then install the snubber bracket ZJ308A 13 On the electronic reverse models connect shift actu ator harness A and gear 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 Install the cap screw coated with blue Loctite 243 securing the driveshaft to the gear case the...

Page 310: ... forth pry the cover up and off the gear case Discard the gasket 742 195C 3 Drain the gear case fluid into a suitable container 4 Remove the shift fork assembly then remove the retaining ring securing the shift fork arm to the shaft and remove the arm Account for the retaining rings O ring and slider blocks ZJ300 NOTE For assembling purposes note the position of the slider blocks on the shift fork...

Page 311: ...ing a soft ham mer tap the output shaft until the slider and output gear assembly come free of the gear case ZJ193 10 Remove the output gear assembly from the slider housing ZJ194 11 Using a suitable bearing puller remove the inner bearing from the transfer gear assembly Account for a spacer washer ZJ195 12 Remove the transfer gear from the planetary gear assembly and account for the thrust washer...

Page 312: ...readed areas for damaged or stripped threads 4 Inspect the bearing areas for cracks or excessive bearing movement If evidence of excessive bearing movement is noted replace the component 5 Inspect the gears for wear cracks or chipped teeth 6 Inspect the input shaft transfer gear bearings for wear scoring scuffing damage or discoloration Rotate the bearings Bearings must rotate freely and must not ...

Page 313: ...bly to the hous ing with the thrust washer and retaining ring ZJ200 3 Using a suitable bearing press install the bearing onto the ring gear ZJ199 4 In order install the thrust washer and then the thrust bearing onto the transfer gear shaft ZJ196 ZJ197 5 Position the planetary gear assembly onto the trans fer gear shaft then install the spacer washer Using a suitable press install the inner bearing...

Page 314: ...itable bearing press and fixture install the input shaft bearing to the gear case then install the oil seal NOTE A light coat of grease must be applied to the seal prior to installing ZJ202 ZJ204 10 Using a suitable press install the input shaft to the gear case cover MS349 11 Install the first retaining ring onto the shift fork shaft then install a new oil seal NOTE Apply a film of grease to the ...

Page 315: ...itch 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 FLUSHING GEAR CASE NOTE Gear case profiles will vary from model to model Determine which style is being serviced and refer to the appropriate illustration 1 Remove the access panels then remove the belt guard 2 Remove the drive belt see Drive...

Page 316: ...drain plug from the gear case then install the drain adapter fitting with hose into the drain plug hole 17 Tip the snowmobile back to the upright position then place a drain pan on the floor next to the drain hose and with the stand in place tip the snowmobile toward its left side far enough to allow the flush fluid to drain from the gear case into the drain pan 18 Secure the snowmobile in this po...

Page 317: ...lease tension on the chain tensioner then remove the ratchet block and chain tensioner assembly PC248A 8 Remove the cap screw and washer securing the upper sprocket to the driven shaft PC249A 9 Remove the retaining ring securing the lower sprocket Remove the sprocket and chain PC250A NOTE If the driven shaft and driveshaft are going to serviced proceed to Cleaning and Inspecting Chain Case If bear...

Page 318: ...ry service work is required 18 Remove the cap screws securing the inner caliper to the tunnel then remove the inner caliper PC148A 19 Pull the driveshaft out to the left then drop out of tunnel right side first PC14 NOTE If the caliper does not remove from the drive shaft easily proceed to step 20 20 Remove the brake pads then remove the outer brake caliper Account for a rubber seal NOTE Place an ...

Page 319: ...EMBLING INSTALLING CHAIN CASE DRIVEN SHAFT DRIVESHAFT TRACK If the driveshaft and driven shaft were not removed pro ceed to step 12 1 Install chain case assembly onto the chassis and secure with six self tapping screws and four machine screws with lock nuts Tighten the self tapping screws to 144 in lb NOTE If an existing chain case is being reinstalled tighten the self tapping screws to 105 in lb ...

Page 320: ...s at 90 to the shaft PC182 9 Secure the PTO side engine mounting plate to the crankcase with four cap screws coated with blue Loctite 243 Tighten to 30 ft lb PC181 10 Install the drive clutch and tighten the clutch cap screw to 51 ft lb then install the driven pulley and drive belt Tighten to 20 ft lb and install the belt guard 11 Tighten the adapter sleeve onto the driven shaft bear ing with the ...

Page 321: ... 144 in lb 15 Fill the chain case with 12 oz of Arctic Cat Trans mission Lube p n 4639 364 16 Connect the speed sensor connector 17 Install the right side footrest support and secure to the belly pan using the torx head screw 18 Install the right side footrest then install the resonator 19 Secure the lower console to the skid panels then install the hood and side panels Drive Train F M XF 1100 REM...

Page 322: ...e cover is removed 7 Place a drain pan under the right side skid plate under the chain case then loosen the eleven screws securing the chain case cover oil tank assembly to the chain case housing 8 Remove the chain case cover oil tank from the chain case Account for a thrust washer on the counter shaft PC073A 9 Remove the reverse gear A reverse fork B reverse shift shaft C and the reverse shift ar...

Page 323: ...re going to serviced proceed to Cleaning and Inspecting Chain Case If bearings and chain or case assembly are to be replaced remove the driven pulley then proceed to step 13 13 Remove the gas tank see Section 4 14 Disconnect the breather hose from oil separator throttle body boots and inlet air temperature sensor connector then remove the air silencer PC161 15 Remove the PTO side chassis support P...

Page 324: ...7 to support the bearing housing and secure with the driven pulley cap screw PC177 19 Bend down the locking tab on the driven shaft chain case bearing adapter sleeve assembly then using the Socket p n 0644 516 loosen the adapter sleeve ring nut Do not remove completely PC153A PC164 20 With the socket on the ring nut lightly tap the socket to disengage the adapter sleeve PC165A CAUTION Keep the bea...

Page 325: ...TE If the calliper does not remove from the driveshaft easily proceed to step 26 26 Remove the brake pads then remove the outer brake caliper Account for a rubber seal NOTE Place an absorbent towel under the caliper to absorb slight amount of brake fluid Do not com press the brake lever PC172 27 Remove the retaining ring securing the brake disc to the driveshaft and remove the brake disc PC175 NOT...

Page 326: ...re not removed pro ceed to step 16 1 Install chain case assembly onto chassis and secure with six self tapping screws and four machine screws with lock nuts Tighten the self tapping screws to 144 in lb NOTE If an existing chain case is being reinstalled tighten the self tapping screws to 105 in lb 2 Place the driveshaft drive sprocket assembly into the tunnel brake end first then into the chain ca...

Page 327: ... to the engine Tighten the upper cap screw to 40 ft lb and the lower to 50 ft lb PC162B 10 Install the right rear engine mount bolt and secure with a new lock nut Tighten securely 11 Install the side chassis support and the left rear engine mount bolt with a new lock nut Tighten securely 12 Install the driven pulley and drive belt Tighten the cap screws securing the driven pulley to 20 ft lb then ...

Page 328: ...ining ring and a smaller thrust washer on the idler shaft PC183A 16 Install the chain tensioner assembly and ratchet block PC085A 17 Install a thrust washer outside the driven shaft sprocket and secure with a retaining ring PC082A 18 Install a thrust washer on the idler shaft then install the reverse sprockets and chain PC085B PC084 19 Secure the driveshaft reverse sprocket to the drive shaft with...

Page 329: ...engine oil 25 Connect the speed sensor connector A the gear indicator switch connector B and reverse actuator connector C PC078 NOTE If the driven shaft was removed proceed with step 26 26 Install the air silencer and gas tank see Section 4 Connect gasline to fuel pump and fuel level fuel pump wire connectors then connect the inlet air tem perature sensor connector 27 Install the right side footre...

Page 330: ...or cracks 7 Inspect the track drive sprockets for wear or damage INSTALLING NOTE The drive sprockets must be installed on the gear case end of the driveshaft Bearcat F Series T Series or the brake side F M XF ZJ216A NOTE Prior to installing the sprockets onto the driveshaft lightly chamfer the inside edge of the sprocket to avoid binding MS362 1 Properly align the scribed line on the driveshaft fr...

Page 331: ...e disc end of the driveshaft MS313C NOTE When pressing new sprockets on the drive shaft align the sprocket alignment marks or the sprockets won t be timed correctly 740 043A 4 Using a calipers measure distances between the sprockets and from the sprockets to each end of the driveshaft for proper location see appropriate illus tration MS364 744 059B 744 060B CAUTION Always press against the tension...

Page 332: ... must also be loosened 743 323A 2 If the measurement is more than specified tighten the adjusting bolts If the measurement obtained is less than specified loosen the adjusting bolts When the measurement is within specification range lock the adjustment by bottoming the jam nuts against the axle housings NOTE On the Bearcat XT tighten the rear axle cap screws to 20 ft lb NOTE Vigorously push the un...

Page 333: ...l revolutions SHUT ENGINE OFF NOTE Allow the track to coast to a stop DO NOT apply the brake because it could produce an inaccu rate alignment condition 4 When the track stops rotating check the relationship of the rear idler wheels and the inner track drive lugs If the rear idler wheels are centered between the inner track drive lugs no adjustment is necessary If not proceed to step 5 0745 809 5 ...

Page 334: ...ecessary Brake System Hydraulic CHECKING BRAKE LEVER TRAVEL 1 Compress the brake lever fully NOTE Do not pump the brake lever as it will pro duce an inaccurate reading 2 Measure the distance between the brake lever and the handlebar The distance must be greater than 1 in 0745 816 3 If the distance is less than specified check the brake fluid level see Checking and Adding Brake Fluid in this sub se...

Page 335: ...compress the brake lever repeatedly until all brake fluid is expelled Close the bleeder valve 3 Add new approved brake fluid to the reservoir then compress the brake lever and hold Open the bleeder valve Repeat the compression until brake fluid flows free of air bubbles and appears clean NOTE It may be necessary to refill the reservoir a number of times to eliminate all air bubbles in the system 4...

Page 336: ... into the caliper for installing new brake pads Replac ing the cover will prevent fluid spillage 2 Open the right side access panel and remove the springs and hairpin clip securing the resonator then remove it from the engine compartment NOTE Measure the thickness of both brake pads The brake pad thickness must be greater than 0 20 in If the brake pad thickness is less than specified replacement o...

Page 337: ...s T Series Removing Disassembling 1 Open the right side access panel then remove the 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 remove the shield and bracket 3 Remove the two torx head cap screws securing the speedometer sensor mounting bracket to...

Page 338: ...ing by using a hammer and sharp flat punch Tap evenly in a crisscross pattern 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 retaining ring securing the inner bearing in the caliper housing ZJ245 12 If bearings are to be replaced place the caliper hous ing i...

Page 339: ...uges cracks pitting scuffing or corrosion If any of these conditions exist replace the piston NOTE The inner and outer caliper housings are not ser viceable components If either or both are defective or dam aged the complete caliper assembly must be replaced 2 Clean the piston outer surface by using a soft Scotch Brite pad and clean brake fluid as a cleaner AF230 WARNING Always wear safety glasses...

Page 340: ...ors Assembling Installing 1 Apply approved brake fluid to the new O ring then install the O ring into the groove of each caliper half ZJ231 2 In each caliper half apply approved brake fluid to the brake piston then while twisting install the pis ton with the dished side facing out ZJ229 ZJ230 NOTE To aid in installing the piston make sure the piston O ring is properly seated in the groove of the c...

Page 341: ...all the bearing spacer then press a new outer bearing into the caliper housing until properly seated ZJ244 NOTE For aid in installing the outer bearing insert a length of shaft the same diameter as the bearing inner bore through the inner bearing driveshaft sleeves and outer bearing to maintain proper align ment of the driveshaft sleeves for driveshaft installa tion CAUTION When installing a beari...

Page 342: ...nstall the Phillips head cap screw and lock nut B then install the four lock nuts A Tighten to 20 ft lb 740 188A 10 Apply Anti Seize Thread Compound to the threads of the brake disc retaining nut then install the nut Tighten only until snug NOTE If the outer caliper housing was removed during disassembling install a new O ring and place the housing into position then secure with the two Allen head...

Page 343: ...oe hook bracket then install the torx head cap screws Tighten securely 17 Place the expansion chamber and resonator into posi tion and secure with the springs and the hairpin clip 18 Adjust track alignment and tension see Track Ten sion and Track Alignment in this section CHECKING AND REPLACING BRAKE PADS F M XF 1 Remove the brake shield then remove the retaining pin securing the brake pads PC195 ...

Page 344: ...n the bleeder valve and compress the brake lever several times to drain the reservoir of fluid 5 Remove the brake hose from the caliper Use an absorbent towel to collect any remaining brake fluid 6 Remove the retaining pin securing the brake pads then remove both pads PC195 NOTE If servicing the brake disc only remove the cap screws securing the caliper housings together then remove the outside ho...

Page 345: ...ed they must be secured together with the seal installed between the inner and outer housings 9 Position a piece of wood between the pistons Using low pressure compressed air blow into the caliper brake hose fitting to loosen the brake pistons PC221A 10 Remove the two screws securing the caliper halves Discard the seal PC219A PC173 11 Remove the pistons A and O rings B then dis card the O rings PC...

Page 346: ...w O rings then install the O rings into the groove of each caliper half 2 In each caliper half apply approved brake fluid to the brake piston then while twisting install the pis ton with the dished side facing out PC201 NOTE To aid in installing the piston make sure the piston O ring is properly seated in the groove of the caliper housing 3 Using a suitable press install a new inner bearing into t...

Page 347: ... Track Alignment in this section 12 Close and secure both side panels Brake Lever Master Cylinder Assembly REMOVING 1 Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other end into a con tainer 739 269B PC223A 2 Remove the two screws securing the reservoir cover and remove the reservoir cover then open the bleeder valve Allow the brake fluid to drain com pletely ...

Page 348: ...e brake fluid hose B to the master cylinder with the banjo fitting bolt A and two new crush washers Tighten securely 3 Install the brakelight switch E to the master cylin der 4 Install the brake lever then secure with pin D and snap ring C Bearcat F Series T Series 5 Place the reservoir cover onto the reservoir then secure with the two screws 6 Bleed the brake system see Bleeding Brake System in t...

Page 349: ...ounting bolts Problem Loss of Brake Condition Remedy 1 Brake fluid overheated contaminated 2 Master cylinder damaged faulty 3 Caliper brake hose leaking 4 Brake lever linkage damaged 1 Replace fluid 2 Replace master cylinder 3 Replace caliper O ring repair piston replace piston O ring brake hose 4 Repair replace lever mounting bolt Problem Brakes Drag Condition Remedy 1 Master cylinder damaged fau...

Page 350: ...Excessive Belt Drag Impaired Drive Clutch Disengagement Condition Remedy 1 Drive clutch components dirty damaged 2 Drive belt does not meet measurement specifications 1 Clean replace drive clutch components 2 Replace drive belt Problem Engine RPM Suddenly Increases Drive Clutch Vibrates Condition Remedy 1 Cam arm pin bent damaged 2 Cam arm damaged broken 3 Drive clutch out of balance 1 Replace pin...

Page 351: ...ics 7 2 Servicing Suspension Bearcat XT 7 5 Servicing Suspension F M XF 7 25 Servicing Suspension Bearcat 570 T Series 7 39 Servicing Suspension F Series 7 57 Rebuilding Recharging Fox Air Shocks 7 74 Servicing Fox Zero Pro Shock Absorbers 7 79 Pressurizing Rebuildable Shocks 7 84 ...

Page 352: ...s the same height off the ground as the rear axle center This pro duces the standard position arrangement 0728 180 Under acceleration when the center of gravity is trans ferred to the rear of the machine the rear suspension col lapses slightly This brings the rear arm point downward and with the front arm stationary the teeter totter effect reduces the pressure on the skis position A However for c...

Page 353: ...e from the shock air valve NOTE As the pump valve is being removed from the shock the sound of air loss is from the pump hose not from the shock 5 Install the air valve cap onto the shock FRONT ARM SPRING TENSION Having very light front arm spring tension is desirable When riding in 4 in or more of snow the machine will be quicker if the front spring tension is adjusted lightly If the spring tensi...

Page 354: ...When making any changes to the front or rear suspension the change should be made at both ends to keep the suspension balanced For example installing stiffer springs in front may require install ing the next step stiffer spring in back to keep every thing in balance ADJUSTING REAR ARM COUPLER The rear arm coupler provides advantages over the stan dard suspension First with the coupler system ski l...

Page 355: ...ap screws securing the skid frame to the tunnel NOTE The support stand should hold the snowmo bile level but not raised off the floor 4 Remove the front cap screws securing the skid frame to the tunnel Account for a flat washer and a lock washer 5 Remove the support stand then using an appropriate handlebar steering post support stand tip the snow mobile onto one side Remove the skid frame End Cap...

Page 356: ...p with the openings windows in the track and from the back start the wear strip onto the rail then using a block of wood and a hammer drive the wear strip forward into position 739 884A 2 Secure with a machine screw and lock nut Tighten to 50 in lb Shock Pads REMOVING 1 Using a 3 16 in drill bit drill out the rivets securing each front shock pad to the slide rail Account for the retaining brackets...

Page 357: ...g a hydraulic press press the bearing out the inside of the wheel C Press the new bearing on its outer race into the idler wheel MS006A D Install the snap ring making sure the sharp side is directed away from the bearing MS007A INSTALLING 1 Secure each idler wheel mounting block on the slide rail with a cap screw and lock nut Tighten to 20 ft lb NOTE For proper alignment install an idler wheel cap...

Page 358: ...nt shock absorber eyelet to the front arm Pull the shock eyelet free of the bracket Account for a serrated axle SC024A 3 Remove the cap screw and lock nut securing the front arm to the slide rail then remove the front arm and account for the serrated axles bushings and an axle tube SC025A MS036A 4 Remove the cap screw and lock nut securing the shock bracket inner idler wheels to the slide rail SC0...

Page 359: ...d for any cracks signs of separation or for unthread ing INSTALLING 1 Secure the shock absorber to the shock bracket with the cap screw and lock nut Tighten securely MS086A NOTE Do not over tighten the shock absorber cap screw as the shock eyelet must be free to pivot 2 Apply grease to the axle and install it into the shock bracket then install the idler wheels and outer spac ers SC027 3 Place the...

Page 360: ... Rear Springs REMOVING 1 With the skid frame removed using the Rear Suspen sion Spring Tool remove the spring from the adjust ing cam MS063 2 Mark the offset arm and the idler arm for assembly purposes Note the flared side of the upper bushing is oriented outwards SC014B 3 Loosen the cap screws securing the offset arm to the idler arm then remove the offset arm assembly Account for two offset arm ...

Page 361: ...tate the idler wheel bearings by hand and inspect for binding or roughness 4 If a bearing must be replaced see Idler Wheels Mounting Blocks Cleaning and Inspecting in this sub section NOTE If the idler wheel has no snap ring securing the bearing the idler wheel is not serviceable 5 Inspect the spring spring slide sleeve washers slide block insert and shaft area for wear 6 Inspect the adjusting cam...

Page 362: ...the centerline of the offset arm assembly then install the offset arm with the flared side of the bushing out Secure the offset arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb SC014A NOTE When tightening the offset arm lock nuts tighten the upper lock nut first to ensure an even clamp load 7 Install the skid frame see Installing Skid Frame in this sub section then install th...

Page 363: ...k the hole that the upper shock links are mounted in for assembling purposes MS076 3 Remove the cap screw and lock nut securing the upper shock links to the idler arm Account for a lock nut spacer and axle links SC020A MS031 4 Remove the cap screw washer and lock nut securing the rear arm to the slide rail Account for the serrated axles and axle tube SC021A MS028 ...

Page 364: ...ler Wheels Mounting Blocks Cleaning and Inspecting in this sub section ASSEMBLING 1 Install the rear arm onto the idler arm with an alumi num axle bushing assemblies and two cap screws coated with blue Loctite 243 Tighten only until snug SC022A 2 Place the rear arm assembly into position Secure with a cap screw washer and lock nut Tighten to 40 ft lb SC021A 3 Place a support beneath the rear arm t...

Page 365: ... Suspension Spring Tool remove the spring from the adjusting cam DISASSEMBLING NOTE When removing center components from the skid frame loosening all axle cap screws lock nuts will make removing easier 1 With the skid frame removed remove the cap screw and lock nut securing the shock absorber to the eye let of the idler arm and remove the shock absorber Account for a sleeve cap screw lock nut and ...

Page 366: ... signs of binding or roughness 6 If the idler wheel bearing must be replaced see Idler Wheels Mounting Blocks Cleaning and Inspecting in this sub section 7 Inspect the shock absorber for any signs of oil leak age especially at the point where the shock shaft enters the shock body 8 Inspect the rubber shock bushings located in the shock absorber eyelets for cracks or deterioration 9 Inspect the sho...

Page 367: ...ing Secure with the cap screw and a new lock nut Tighten to 40 ft lb SC033 SC032 5 Position the shock links in the appropriate holes of the idler arm brackets as marked during disassem bling Place a spacer between the center of the brackets then insert the link axles into the upper shock link eyelets Secure with a cap screw washer and lock nut Tighten securely SC031A 6 Secure the shock absorber to...

Page 368: ...ing the wear strip to the front of the slide rail 3 Using a suitable driving tool drive the wear strip off the rail AG510D 4 Remove the cap screws and lock nuts securing the front arm limiter straps to the rail support 5 Remove the cap screws securing the rail supports to the slide rail 6 On the slide rail being replaced remove the cap screws and lock nuts securing the inner and outer idler wheels...

Page 369: ...e rail 9 Remove the cap screw and flat washer securing the spring slide and overload spring to the rail Account for a spacer the slide block overload spring retainer clips bushing one small washer and two large washers SC040A MS108 10 Remove the cap screw and lock nut securing the overload spring tension block to the slide rail SC041A 11 Remove the cap screw and lock nut securing the rear arm shoc...

Page 370: ...ont Arm Shock Bracket Axle C Front Arm D Rear Arm SC044A SC043B NOTE Take care that all the shim washers and spacers are in place on the center components of the slide rail 2 Install the rear arm limiter and secure with cap screw coated with blue Loctite 243 and tighten to 40 ft lb SC042A 3 Secure the two front rail supports with cap screws coated with blue Loctite 243 Tighten to 20 ft lb SC047A 4...

Page 371: ...nt MS121A 9 Secure the outer idler wheel to the mounting block with a cap screw flat washers idler wheel and a lock nut Tighten to 20 ft lb MS122 10 Secure the end cap onto the slide rail using a cap screw flat washers and a lock nut Tighten to 80 in lb MS206A NOTE 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 then u...

Page 372: ...om one side slide the rear axle I out from between the swing arm and account for the two idler wheel spacers J and two washers K 6 Remove the two cap screws and lock nuts L secur ing the adjuster blocks M to the swing arm INSPECTING 1 Inspect each idler wheel and plastic hub for cracks or damage 2 Rotate the idler wheel bearings by hand and inspect for binding or roughness 3 Inspect all bushings f...

Page 373: ...djusting the lock nuts on the spring brackets until both rear idler wheels are 1 in off the work surface Installing Skid Frame 1 Using an appropriate handlebar steering post support stand tip the snowmobile onto one side 2 Pull the track away from the tunnel and spread open then place the skid frame into the track 3 Position the front of the skid frame into the tunnel and align the front arm with ...

Page 374: ...ate hole in the tunnel Secure the offset arm assembly with a cap screw lock washer and flat washer TIGHTEN ONLY UNTIL SNUG NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 7 At this time place the snowmobile to the upright position then tighten both rear arm mounting cap screws to 40 ft lb NOTE At this point tighten all remaining skid frame mounting hardw...

Page 375: ...and tip the snowmobile onto one side 4 On the F slide the skid frame rearward far enough to drop the front arm out of the slider axle then remove the skid frame 5 On the M and XF remove the two cap screws and nuts securing the front of the skid frame to the chas sis Account for two washers End Caps REMOVING 1 Remove the lock nut and cap screw securing the end cap FZ096B 2 Using a hammer tap the en...

Page 376: ...hock Pads REMOVING 1 Remove torx head screws and nuts securing the shock pads 2 Remove the rear shock pads INSPECTING 1 Inspect the pads for damage or wear 2 Inspect the rivet holes in the slide rail for damage or elongation INSTALLING 1 Place the pads brackets into position on the slide rail 2 Secure the pads with existing torx head screws and nuts Idler Wheels Mounting Blocks REMOVING 1 Remove t...

Page 377: ...ly REMOVING 1 With the skid frame removed remove the cap screws and lock nuts securing the limiter straps to the front arm Account for flat washers 2 Remove the cap screw and lock nut securing the upper front shock absorber eyelet to the front arm Pull the shock eyelet free of the bracket Account for a sleeve ZJ271A 3 Remove the lock nut and cap screw securing the rear shock pivot to the front arm...

Page 378: ...ghten to 20 ft lb NOTE For proper alignment install an idler wheel cap screw and lock nut into the top mounting block hole prior to tightening 4 Secure the idler wheel to the mounting block with both existing cap screw Tighten cap screws to 20 ft lb 5 Install the axle into the front arm then position the front arm to the mounting location of the slide rail Secure with cap screws and lock nuts Tigh...

Page 379: ...ove the spring and sleeve from the idler arm NOTE Use the same procedure for the other side 7 Remove the cap screw and lock nut securing the upper shock eyelet to the idler arm then remove the cap screw and lock nut securing the upper shock link to the idler arm Account for the cap screws lock nuts and sleeves 8 Remove the cap screw A and lock nut securing the rear arm shock absorber to the rear s...

Page 380: ...ess 7 If a bearing must be replaced see Idler Wheels Mounting Blocks Cleaning and Inspecting in this sub section INSTALLING 1 Place the rear arm assembly into position between the slide rails Secure with a cap screw and lock nut Tighten to 40 ft lb FZ103A 2 Install the rear arm onto the idler arm with an alumi num axle and two cap screws Tighten to 40 ft lb FZ101A 3 With the sleeves installed inst...

Page 381: ...ng with a thin flat washer through the notched side of the offset arm assembly NOTE If the flared bushing in the offset arm is loose it must be cleaned and green Loctite 609 must be applied to it prior to installation 10 Align the marks on the idler arm to the centerline of the offset arm assembly Secure the offset arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb FZ048A NOTE ...

Page 382: ...loosen and remove the remaining cap screw from the rear arm idler arm it may be neces sary to reinstall the cap screw 5 Remove the cap screw and lock nut securing the rear arm to the slide rail Account for the bushings and axle tube XM007A CLEANING AND INSPECTING 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 ...

Page 383: ... the sleeves installed position the shock link in the appropriate holes of the idler arm brackets and shock absorber then insert the cap screw through the eyelets Secure with the cap screws and lock nuts Tighten securely XM003A 5 Install the inner carriage axle to the idler arm then install a wave washer and idler wheel Secure with the snap ring XM002 6 Turn the slide rail onto the side the idler ...

Page 384: ...and flat washers Tighten cap screws only until snug NOTE Tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted then the axle assembly must be tightened to 34 ft lb 3 Install the skid frame see Installing Skid Frame in this sub section Slide Rails REMOVING NOTE When replacing one or both slide rails is necessary remove one slid...

Page 385: ...Discard the lock nut FZ058A NOTE If removing the cap screws from the front shock axle is necessary to replace the slide rail install the cap screw from the opposite side into the assembly to secure components and aid in replacing the slide rail 7 On the F remove the lock nut cap screw and flat washer securing the spring slide to the rail Account for a spacer and the slide block FZ059A NOTE On the ...

Page 386: ...rm slider bumpers for cracks or wear INSTALLING 1 Insert the track adjuster bracket through the slot in the slide rail then thread the adjuster cap screw into the bracket 2 With the slide rail assembly on its side place the rail that was removed or replaced into position then finger tighten the cap screw securing the rear arm to the rail 3 Secure the front arm to the slide rail with the cap screw ...

Page 387: ...ck prior to tighten ing 10 Secure the rail supports with cap screws Tighten to 20 ft lb FZ077 11 With the spacer on the front rail support centered between the limiter straps secure the straps to the rail support with the cap screw washers and lock nut Tighten to 120 in lb 12 Secure the end cap onto the slide rail using a cap screw flat washers and a lock nut Tighten to 80 in lb FZ096B NOTE Use a ...

Page 388: ...er and flat washer AT THIS TIME TIGHTEN ONLY UNTIL SNUG 7 Tip the snowmobile onto the other side then align the offset arm assembly with the appropriate hole in the tunnel Secure the rear arm assembly with a cap screw lock washer and flat washer AT THIS TIME TIGHTEN ONLY UNTIL SNUG NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 8 At this time place the ...

Page 389: ...securing the skid frame to the tunnel Account for lock washers and flat washers NOTE The support stand should hold the snowmo bile level but not raised off the floor 4 Remove the support stand then using an appropriate handlebar steering post support stand tip the snow mobile onto one side 5 Slide the skid frame rearward far enough to drop the front arm out of the slider axle then remove the skid ...

Page 390: ...ard into position 2 Secure with a machine screw and lock nut Tighten to 50 in lb Shock Pads REMOVING 1 Using a 3 16 in drill bit drill out the rivets securing each front shock pad to the slide rail Account for the retaining brackets 2 Remove the torx head screws and lock nuts securing the rear shock pads to the slide rail then remove the shock pads INSPECTING 1 Inspect the pad and retaining bracke...

Page 391: ...eel MS006A D Install the snap ring making sure the sharp side is directed away from the bearing MS007A INSTALLING 1 Secure the mounting block on the slide rail with a cap screw and lock nut Tighten to 20 ft lb NOTE For proper alignment install an idler wheel cap screw into the top mounting block hole prior to tightening TZ025 2 Place the idler wheel to the mounting block then secure the idler whee...

Page 392: ...ECTING 1 Inspect all front arm weldments for cracks or unusual bends then inspect the front arm mounting brackets for cracks and for elongated holes 2 Closely inspect all tubing for cracks or unusual bends 3 Inspect the bearings bushings and front arm spacers for wear or damage 4 Inspect the shock absorber for damage and for any signs of oil leakage especially at the point where the shock shaft en...

Page 393: ...w and a lock nut Tighten cap screw to 20 ft lb TZ026 5 Install the axle into the front arm then position the front arm to the mounting location of the slide rail Secure with cap screws and lock nuts Tighten to 40 ft lb TZ028A 6 Secure the upper shock eyelet and axle in the mount ing hole of the front arm Secure with a cap screw and lock nut Tighten securely ZJ271A NOTE Do not over tighten the shoc...

Page 394: ...ly Account for a flanged axle idler spacer and washer TZ004A FZ036 4 Remove the idler wheel NOTE Use the Idler Wheel Puller Kit 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 TZ007A NOTE If the overload spring is being removed use a punch to drive the ...

Page 395: ...e cap screws lock nuts and sleeves TZ010A TZ011A NOTE For assembling purposes note the mount ing location of the shock links to the idler arm 8 Remove the cap screw and 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 screw and lock nut securing the re...

Page 396: ...adjusting cams for damage 6 Rotate the idler wheel bearings by hand and check for binding or roughness 7 If a bearing must be replaced see Idler Wheels Mounting Blocks Cleaning and Inspecting in this sub section INSTALLING 1 Place the rear arm assembly into position between the slide rails Secure with a cap screw and lock nut Tighten to 40 ft lb TZ016A 2 Install the rear arm onto the idler arm wit...

Page 397: ... along with the cap screw and lock nut then secure the shock absorber links and spacer to the upper mounting hole of the idler arm with cap screws and lock nuts Tighten securely TZ010B NOTE Do not over tighten the shock absorber cap screw as the shock eyelet must be free to pivot TZ020A NOTE Make sure the spacer is installed between the brackets of the idler arm before securing the shock links 7 S...

Page 398: ... the offset arm is loose it must be cleaned and green Loctite 609 must be applied to it prior to installation 12 Align the marks on the idler arm to the centerline of the offset arm assembly Secure the offset arm to the idler arm with cap screws and lock nuts Tighten to 20 ft lb TZ004B NOTE When tightening the offset arm lock nuts tighten the lower lock nut first to ensure an even clamp load Make ...

Page 399: ...le and secure with two cap screws E coated with blue Loctite 243 and large flat washers Tighten cap screws only until snug NOTE Care must be taken that the adjuster bushing slot with the cap screw hole is aligned properly with the adjuster bolt MS058A ZJ266 NOTE Tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted then the ax...

Page 400: ...5 Remove the cap screws and lock nuts securing the front outer idler wheel and the idler wheel mounting block TZ033A TZ034A 6 Remove the lock nut from the cap screw securing the front shock axle assembly to the slide rail TZ035A NOTE If removing the cap screws from the front shock axle is necessary to replace the slide rail remove the front outer idler wheel and install the cap screw from the oppo...

Page 401: ...screw is necessary to replace 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 10 Remove the cap screw lock nut and flat washer securing the spring slide and overload spring to the rail then using a suitable driving tool remove the bushing securing the overload spring to the rail Account for a spacer the sli...

Page 402: ...slide rail Account for the block bush ing cap screw and lock nut TZ046A 14 Remove the lock nut from the cap screw securing the rear arm assembly to the slide rail TZ046B NOTE If removing the cap screw is necessary to replace the slide rail install the cap screw from the opposite side into the assembly to secure the compo nents and aid in replacing the slide rail 15 Remove the torx head cap screws ...

Page 403: ...ure the track adjuster bracket with the cap screws and lock nuts Tighten to 120 in lb 3 Secure the front arm to the slide rail with the cap screws and lock nuts Tighten to 40 ft lb TZ050 NOTE At this point return to step 1 and tighten the rear arm and front arm cap screws and lock nuts to 40 ft lb then tighten the rear arm pivot idler wheel assembly to 20 ft lb 4 Install coupler block w bushing Se...

Page 404: ...d a lock nut Tighten to 20 ft lb TZ053A 10 Install the inner idler wheel mounting block and secure with cap screws and lock nuts Tighten to 20 ft lb TZ035B NOTE To obtain proper alignment for the idler wheel cap screw place the cap screw in the top hole through the rail and mounting block prior to tighten ing 11 Secure the outer idler wheel mounting block with the cap screw and lock nut Tighten to...

Page 405: ...rip onto the rail then using a soft hammer drive the wear strip forward into position Secure with a torx head screw and lock nut Tighten to 50 in lb TZ057 FZ026B 16 Install the skid frame see Installing Skid Frame in this sub section then install the rear arm springs onto the adjuster blocks Installing Skid Frame 1 Using an appropriate handlebar steering post support stand tip the snowmobile onto ...

Page 406: ...at washer TIGHTEN ONLY UNTIL SNUG NOTE Do not install the short legs of the rear springs onto the adjusting cams at this time 7 At this time place the snowmobile to the upright position then tighten both rear arm mounting cap screws to 40 ft lb NOTE At this point tighten all remaining skid frame mounting hardware to 40 ft lb 8 Using the Rear Suspension Spring Tool install the short legs of the rea...

Page 407: ...e rear arm assembly cap screws securing the skid frame to the tunnel NOTE The support 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 frame rearward far enough to drop the front arm out of the slider axle then remove the skid frame End Caps REMOVING 1 Rem...

Page 408: ...and from the back start the wear strip onto the rail then using a block of wood and a hammer drive the wear strip forward into position 2 Secure with a machine screw and lock nut Tighten to 50 in lb Shock Pads REMOVING 1 Using a 3 16 in drill bit drill out the rivets securing the front shock pads to the slide rail Account for the retaining brackets 2 Remove the rear shock pads INSPECTING 1 Inspect...

Page 409: ...el MS006A D Install the snap ring making sure the sharp side is directed away from the bearing MS007A INSTALLING 1 Secure the mounting block on the slide rail with a cap screw and lock nut Tighten to 20 ft lb NOTE For proper alignment install an idler wheel cap screw into the top mounting block hole prior to tightening FZ031A 2 Place the idler wheel to the mounting block then secure the idler whee...

Page 410: ...p screw and flat washer FZ029A 7 Remove the cap screw and lock nut securing the idler wheel mounting block to the slide rail NOTE For ease of removal remove the front outer idler wheel and mounting block from the side of the slide rail in which the front arm shock axle cap screw was installed 8 Remove the cap screws washer and lock nut from the front shock axle then from one side tap the assembly ...

Page 411: ...screw washer and a new lock nut Tighten to 40 ft lb FZ053 3 On the side that the idler wheel and mounting block were removed from secure the mounting block on the slide rail with a cap screw and lock nut Tighten to 20 ft lb NOTE For proper alignment install an idler wheel cap screw and lock nut into the top mounting block hole prior to tightening FZ055A 4 Secure the idler wheel to the mounting blo...

Page 412: ... lock nuts Tighten to 120 in lb ZJ270 Rear Arm Assembly REMOVING 1 With the skid frame removed using the Rear Suspension Spring Tool remove the spring from the adjusting cam FZ033A 2 Mark the offset arm and the idler arm for assembly purposes FZ034 3 Loosen the cap screws and lock nuts securing the offset arm assembly to the idler arm then remove the offset arm assembly Account for a flanged axle ...

Page 413: ...arm then remove the cap screw B and lock nut securing the upper shock link to the idler arm Account for the cap screws lock nuts and sleeves FZ040C 8 Remove the cap screw A and lock nut securing the rear arm shock absorber to the rear shock pivot then remove the cap screw B and lock nut securing the shock absorber link to the pivot and account for the cap screws lock nuts and sleeves FZ041C 9 Remo...

Page 414: ...ls Secure with a cap screw and lock nut Tighten to 40 ft lb FZ043 2 Install the rear arm onto the idler arm with an alumi num axle and two cap screws Tighten to 40 ft lb FZ044 3 With the sleeves installed install the shock absorber link to the lower mounting hole of the rear shock pivot then install the shock absorber with cap screws A and B and lock nuts Tighten securely FZ041C 0742 877 4 With th...

Page 415: ...Place the spring slide and 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 MS014 FZ045 7 With a suitable driving tool install the rear upper idler wheel on the idler arm FZ046 MS072A 8 Install the idler spacer collar onto the idler arm CAUTION When driving the idler wheel onto the idler arm use a tool to contact the insi...

Page 416: ...1 Grease the idler arm and rear arm grease fittings with an all temperature grease Rear Axle Idler Wheels DISASSEMBLING REAR AXLE 1 With the skid frame removed remove the cap screw and large flat washer securing the outer rear idler wheel Remove the outer idler wheel from the shaft FC194 2 Loosen the track adjusting bolts Slide the outer adjuster bushings off the axle ZJ266 3 Carefully slide the s...

Page 417: ...r both slide rails is necessary remove one slide rail at a time The remaining slide rail will then hold the crossbraces axles and brackets in their correct assembly order Always mark the mounting hole locations during dis assembly to speed up the assembly process and to prevent any damage 1 With the skid frame removed remove the machine screw and lock nut securing the wear strip to the front of th...

Page 418: ... in replacing the slide rail 7 Remove the lock nut cap screw and flat washer securing the spring slide to the rail Account for a spacer and the slide block FZ059A NOTE If not already done remove the short spring leg from the adjusting cam 8 Note the mounting location for installing purposes then remove the cap screws and lock nuts securing the inner idler wheel and mounting block 9 Remove the cap ...

Page 419: ...s at the beginning of this procedure INSPECTING 1 Inspect the slide rail for cracks elongated holes or unusual bends 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 strips is necessary 3 Inspect the front arm slider bumpers for cracks or wear INSTALLING 1 Secure the track adjuster brack...

Page 420: ...lat washer Tighten only until snug FZ066 NOTE Care must be taken that the adjuster bushing slot with the hole is aligned properly with the adjuster bolt CM261A NOTE Tighten the rear idler wheel axle only until snug until the skid frame has been installed and track tension has been adjusted then the axle assembly must be tightened to 20 ft lb 6 Install coupler block w bushing Secure with cap screw ...

Page 421: ... wheel cap screw place the cap screw in the top hole through the rail and mounting block prior to tighten ing FZ073A 10 Secure the outer idler wheel mounting block with the cap screw and lock nut Tighten to 20 ft lb then secure the outer and inner idler wheels to the mount ing blocks with existing hardware Tighten to 20 ft lb ZJ288 NOTE To obtain proper alignment for the idler wheel cap screw plac...

Page 422: ...rip onto the rail then using a soft hammer drive the wear strip forward into position Secure with a torx head screw and lock nut Tighten to 50 in lb MS207 MS016B 15 Install the skid frame see Installing Skid Frame in this sub section then install the rear arm springs onto the adjuster blocks Installing Skid Frame 1 Using a piece of cardboard on the floor to protect against scratching tip the snowm...

Page 423: ...h 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 at this time 7 At this time place the snowmobile to the upright position then tighten both rear arm assembly mount ing cap screws to 40 ft lb 8 Using the Rear Suspension Spring Tool install the short legs of the rear springs onto the adjustin...

Page 424: ... wear 4 Clean shaft threads and eyelet threads 5 Apply red Loctite 271 to both threads install the eyelet and tighten securely DISASSEMBLING 1 Remove the valve cap then bleed the air from the air chamber FS141 2 While holding the end cap unscrew the air cham ber FS142 NOTE The air chamber should only be hand tight 3 Drain the oil from the air chamber 4 Remove the air chamber from the bottom of the...

Page 425: ...er half turn FS146 7 Using Inflation Needle remove all the nitrogen from the shock FS147 8 Using a 5 64 in Allen wrench remove the set screw from the bearing cap PC244 9 Using a magnet remove the bleed ball PC245 10 Using Spanner Wrench loosen the bearing cap PC246 11 Remove the shock rod piston assembly from the shock body FS151 ...

Page 426: ...ston with shock oil FS154 2 Carefully install the floating piston into the shock body until it is below the threads FS155 3 Using Floating Piston Location Gauge install the floating piston while using the inflation needle to vent the shock body NOTE Refer to the Suspension Specifications Shock Absorbers sub section in Section 1 FS156 4 Using Fox Racing Shock Oil fill the shock body to the bottom o...

Page 427: ...ng cap into position FS160 8 Using Spanner Wrench tighten the bearing cap PC246 NOTE When tightening the bearing cap note air and excess oil being bled from the hole in the cap 9 Install the bleed ball and set screw into the bearing cap PC245 PC244 10 Charge the shock with nitrogen to 200 psi FS164 11 Using a 3 16 in Allen wrench tighten the nitrogen bladder ...

Page 428: ...E Prior to installing the air chamber make sure the end cap 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 Shock Absorber Air Pump as an initial setting inflate the air chamber to 75 psi for the F Sno Pro and XF Sno Pro models or 90 psi for the M Sno Pro models and HCR models NOTE The rear arm shock sho...

Page 429: ... 2 Clean the entire shock assembly with soapy water Dry the shock assembly with compressed air NOTE If compressed air is not available use clean towel to dry the shock assembly 3 Clamp the body eyelet of the shock securely in vise with shaft side up 4 Remove the button head screw from the nitrogen valve in the shock body FS040 5 Insert the Inflation Needle squarely into center of the nitrogen valv...

Page 430: ...osen and remove the nitrogen valve from the body FS014 13 Remove the shock body from the vise then invert the shock body and place it on a folded shop towel open end down 14 Using compressed air NEVER USE HIGH PRES SURE NITROGEN insert the air gun nozzle into the nitrogen valve port and blow the IFP out of the shock body and onto the folded shop towel FS012 15 Clean the body tube reservoir tube an...

Page 431: ...ring Check to make sure the O ring is properly seated and is not twisted NOTE To aid in proper seating of the O ring it may be advisable to use a soft blunt object non writing end of a pen etc to push it in 6 Install the new well lubricated O rings into the bear ing housing making sure the shaft O ring is in the groove next to the DU bushing and that the O rings are properly seated and not twisted...

Page 432: ...s FS015 7 Using Floating Piston Location Gauge install the floating piston while using the inflation needle to vent the shock body NOTE Refer to the Suspension Specifications Shock Absorbers sub section in Section 1 NOTE Depth is measured from the edge of the body opening to the outside edge of the IFP not the center depression of the IFP 8 Lubricate the O ring on the nitrogen valve with assem bly...

Page 433: ... of the nitro gen valve taking care that the valve is directed away from face and body and pressurize the reservoir to 200 psi The shock shaft should be fully extended from the pressure before the final pressure reading is taken Continue charging while pulling the reservoir away from the needle using a smooth straight motion Keep the reservoir as straight as possible to prevent the needle from ben...

Page 434: ...ition smoothly NOTE If a soft spot or a mushy area is felt as the shaft is pushed down this would indicate air in the shock body If there is air in the shock body dis charge the reservoir gas pressure Disassemble the shock to the point that the filling with oil and the bleeding air procedures can be redone Assemble and repeat the pressurizing procedure To test the shock absorber for nitrogen gas l...

Page 435: ...rcat F Series T Series 8 22 Ski Shock Absorber 8 23 Sway Bar F XF 8 24 Sway Bar F Series T Series 8 24 Front Suspension Mounting Bracket Bearcat F Series T Series 8 24 Front Bumper F M XF 8 28 Seat Assembly F M XF 8 28 Seat Assembly Bearcat F Series T Series 8 29 Seat Cushion 8 29 Taillight Brakelight Assembly 8 30 Backrest Rack Assembly Bearcat 8 31 Rear Bumper Snowflap Bearcat F Series T Series ...

Page 436: ...t of the access panel Move the panel up and off the pin then swing the panel all the way out and unhinge the panel from the lower console 2 Remove the two torx head screws securing the hood located on the underside of the hood above the rear tube of the upper A arm then remove the two torx head screws from the top side of the hood securing the hood to the upper console NOTE On the turbo models rem...

Page 437: ...e rod link to the second ary steering post then remove the two machine screws and nuts securing the top of the secondary steering post to the chassis Account for both steer ing post blocks and retaining plate SNO 2226B 9 Carefully remove the steering post from the snow mobile 10 On adjustable steering models remove and discard the cotter pin C and nyloc nut B securing the steering post to the lowe...

Page 438: ...hen secure the steering post using the existing retaining ring NOTE Verify the bushings are properly oriented the seam should be centered front to back 2 Install the adjusting block onto the steering post and secure using the existing snap ring 3 Install the steering post assembly onto the front and rear spar tubes and into the thrust washer A and the lower steering post support Secure with the ex...

Page 439: ...s are in position NOTE On the 1100 cc non turbo models make sure the foam seal is in place on the air intake NOTE On the turbo models make sure the air filter housing is properly connected and secured with the rubber straps to the intake plenum of the hood and turbocharger 13 Install the access panel onto the lower console then close the access panel and secure with the hairpin clip Steering Post ...

Page 440: ...ke pipe and the turbocharger then carefully work the intercooler upward until it releases from the rubber grommets 8 On the non turbo TZ1 remove the two cap screws A securing the front end close off cover to the chassis ZJ020A NOTE For installing purposes note the location of the exhaust pipe mounting tab B 9 Remove and discard the lock nut securing the steer ing tie rod to the steering post ZJ156...

Page 441: ...to the upper support plate with the bracket plates and cap screws coated with blue Loctite 243 Tighten the cap screws to 96 in lb FS182A NOTE When installing the bracket plates the wider end of the plate must be directed up FS200A 4 On the Bearcat 570 F Series T Series place the rub ber exhaust bumper into position on the air silencer FS203A 5 Place gaskets on the resonator and exhaust manifold th...

Page 442: ...ndlebar is properly secured 12 After the handlebar is locked in position release the cam lever and rotate it one turn clockwise then press down on the cam lever until it locks in place NOTE At this point gently lift the cam lever without pressing in on the lock pin If the cam lever cannot be lifted the lock pin is secure 13 Secure the console to the steering support with the torx head screws and t...

Page 443: ... from the back side of the ski cap screw and spread the pin Ski Wear Bar The ski wear bar is a replaceable bar attached to the underside of the ski If the snowmobile is operated pri marily in deep snow ski wear bar wear will be minimal however if the snowmobile is operated on terrain where the snow cover is minimal the ski wear bar will wear faster Arctic Cat recommends that the ski wear bars be r...

Page 444: ...se then remove the cap screws and lock nuts E securing the steer ing arms to the drag link Remove the arms and account for the axles F inside the steering arms NOTE With the steering arms removed note the direction of the steering arms for installing purposes ZJ161A 6 If replacing using a suitable punch drive the two bearings out of the drag link ZJ162 INSPECTING 1 Inspect the entire drag link esp...

Page 445: ... then connect the oxygen sensor and install the hood 7 Using an all temperature grease grease the steering arms then verify free movement of the steering com ponents ZJ165A NOTE On the F5 LXR to finalize the installing of the drag link proceed to Air Silencer Liquid Cooled F 2 Stroke sub section in Section 3 and follow the INSTALLING procedure Tie Rods Bearcat F Series T Series REMOVING AND DISASS...

Page 446: ...ont of the snowmobile up on a safety stand 2 Remove the ski 3 Remove the tie rod cap and lock nut securing the tie rod ball joint to the spindle then remove the ball joint from the spindle NOTE Note whether the tie rod is installed on the top side or on the bottom side of the spindle arm for installing purposes 4 Remove the spindle cap and snap ring from the top of the spindle then remove the cap ...

Page 447: ...the jam nut then remove the ball joint from the tie rod NOTE Replacing the ski bolt bushings is difficult The existing bushings will be damaged during removal Be careful however not to damage the spin dle when removing the bushings Press the new bushings 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 unti...

Page 448: ...p ring and spindle cap ZJ172 9 Place the steering tie rod ball joint into position on the steering arm as noted during removing and secure with a lock nut Tighten to 30 ft lb then install the tie rod cap 10 Install the ski and tighten to 26 ft lb 11 Remove the safety stand from beneath the front end Spindle F M XF REMOVING 1 Position the front of the snowmobile on a safety stand then remove the sk...

Page 449: ...lacing the ski bolt bushings is difficult The existing bushings will be damaged during removal Be careful however not to damage the spin dle when removing the bushings Press the new bushings into the spindle INSTALLING 1 Place the shock absorber into position on the spindle Secure with the cap screw and nyloc nut Tighten to 32 ft lb PC087A 2 Install the upper and lower A arms into the spindle then...

Page 450: ...teering arm Discard both nuts PC099B 2 Remove the nyloc nuts securing the steering tie rod ends to the spindle arms Account for the washers and discard both nuts PC088A 3 Slide the steering tie rod out of the steering boot and out of the snowmobile 4 Remove the nyloc nut securing the tie rod end to the steering arm Discard the nut PC099A 5 Remove the nyloc nut securing the tie rod to the steering ...

Page 451: ... steering tie rod bracket Secure with a new nyloc nut Tighten to 20 ft lb PC099A 4 Slide the steering tie rod through the steering boot and into the snowmobile then place the steering tie rod into the spindle arm with the washer Secure with a new nyloc nut Tighten to 32 ft lb PC088A 5 Secure the steering tie rod to the steering tie rod bracket with the screw and new nyloc nut Tighten to 20 ft lb P...

Page 452: ...he rubber exhaust bumper into position on the air silencer FS203A 6 Place gaskets on the resonator and exhaust manifold then install the expansion chamber Secure the cham ber to manifold and upper frame with the springs Ski Alignment CHECKING NOTE Track tension and alignment must be properly adjusted prior to checking or adjusting ski alignment Ski alignment must be performed on a flat level surfa...

Page 453: ...nt 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 rod flats rotate the spindle tie rod until recommended specification is attained 4 Apply blue Loctite 243 to each jam nut thread area then tighten the jam nuts against the inner tie rod Tighten to 13...

Page 454: ...ion 5 Remove the two lock nuts securing the spindle to the A arms then using a rubber mallet remove the arms from the spindle Discard the nuts PC089A PC090A 6 On the F XF remove the cap screw and lock nut secur ing the sway bar link to the lower arm Discard the nut PC093A 7 Remove the two cap screws and nyloc nuts securing the lower arm to the chassis then slide the boot from the arm and remove th...

Page 455: ...e chassis and secure with the cap screws and new nyloc nuts Tighten to 23 ft lb NEW NOTE On the turbo models install the front left fas cia using the existing torx head screws 2 Slide the lower arm into the boot then place the arm into position on the chassis Secure with the cap screws and new nyloc nuts and tighten to 55 ft lb front and 45 ft lb rear PC095A 3 On the F XF secure the sway bar link ...

Page 456: ...e upper arms to the spindle with the cap screw and lock nut Tighten to 32 ft lb REMOVING LOWER A ARM NOTE On the F5 LXR to remove the lower A arms it will be necessary to remove the air silencer Proceed to Air Silencer F5 LXR sub section in Section 3 and follow REMOVING procedure 1 Elevate the front of the snowmobile with a suitable safety stand or lift 2 Remove the cap screw and lock nut securing...

Page 457: ... 6 Install the shock absorber to the spindle then install the cap screw and lock nut Tighten to 32 ft lb NOTE On the F5 LXR to finalize the installing of the lower A arms proceed to Air Silencer F5 LXR sub section in Section 3 and follow the INSTALLING pro cedure Ski Shock Absorber REMOVING 1 Position the front of the snowmobile on a safety stand taking all pressure off the skis 2 Remove the cap s...

Page 458: ...y bar mounting brackets to the chassis then using a soft hammer tap the sway bar in either direction until the sway bar link is off the pin on the A arm 0744 929 2 Slide the sway bar out of the chassis and account for the sway bar links and four sleeves INSPECTING 1 Inspect the sway bar for any signs of twisting fatigue or wear 2 Inspect the sway bar links for cracks or damage INSTALLING 1 Place t...

Page 459: ...r the sleeves 9 Remove the sway bar links D from the pins of the left side right 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 remove all cap screws and lock nuts corresponding to E securing the right side upper A arms and lower A arm to the suspensi...

Page 460: ...8 26 0744 930 ...

Page 461: ...stalling the A arms make sure the axle shoulders are properly positioned ZJ168A 7 Install the right side steering arm with cap screw and lock nut H 8 To install the left side steering components first place the sway bar into the sway bar link on the right side A arm then move the sway bar to the mounting position 9 Install the left side shock absorber with sleeve to the shock mounting frame with c...

Page 462: ...ide and right side panels with the self tapping screws ZJ166B 20 Secure the bottom of the assembly to the suspension mounting bracket with the two body screws and lock nuts Tighten securely then install the hood ZJ167A NOTE On the F5 LXR to finalize the installing of the front suspension mounting bracket proceed to Air Silencer F5 LXR sub section in Section 3 and follow INSTALLING procedure Front ...

Page 463: ...crews D and the body screws securing the knee pads to the gas tank and the steering sup port then secure the rear side panels spars with the three torx head cap screws C for each side 2 Install the handlebar close off panel then secure the panel with the two torx head cap screws B Posi tion the console assembly on the headlight support bracket then connect the main hood harness 3 Install the conso...

Page 464: ... 329 2 Compress the latch on the right side of the front seat and lift the front seat 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 hole in the storage compartment panel then remove the harness from beneath the seat Speedrack mount 5 Remove the two se...

Page 465: ...the washers and lock nuts Tighten securely 3 In turn on each side install the 1 4 in cap screw in the front hole and the 5 16 in cap screw in the rear hole Secure with a flat washer and lock nut Tighten securely 4 If applicable connect the passenger handwarmer wiring harness 5 Place the rack into position and secure with the cap screws washers and cap nuts Rear Bumper Snowflap Bearcat F Series T S...

Page 466: ...ble steer ing models into the lower holes in the handlebar riser from the left side and tip the snowmobile onto its left side 3 Swing the skid frame assembly away from the chas sis then using a 3 16 in drill bit remove all rivets securing the left side of the bumper then repeat for opposite side 4 Remove and retain the two machine screws and nuts securing the front of the existing bumper to the ch...

Page 467: ... enough to allow the headlight housing to be installed then install the housing making sure the forks of the housing go into the grommets on top of the air silencer Secure with the cap screw and lock nut 743 439A 4 Position the console onto the air silencer then secure with the single torx head cap screw beneath the con sole located between the headlights 5 Install the two torx head screws located...

Page 468: ...curing the console to the chassis then lift up the rearward end of the con sole and disconnect the console harness plug in 0743 777 2 Remove the console INSTALLING CONSOLE 1 Place the console into position on the headlight sup port bracket then connect the console harness plug in 2 Secure the console to the chassis with the two torx head screws Windshield Console Headlight F M XF REMOVING 1 Remove...

Page 469: ...e bulb portion of the headlight is fragile HANDLE WITH CARE When replacing the headlight bulb the bulb assembly must first be removed from the housing Do not touch the glass portion of the bulb If the glass is touched it must be cleaned with a dry cloth before installing 1 Disconnect the headlight harness connector from the bulb then remove the rubber grommet from the headlight housing 2 Rotate th...

Page 470: ...ming surface directly in front of the headlight 5 Engage the brake lever lock and start the engine Select the headlight dimmer switch HIGH beam position DO NOT USE LOW BEAM 6 Observe the headlight beam aim Proper aim is when the most intense beam is centered on the vertical mark 5 cm 2 in below the horizontal mark on the aiming surface 7 Adjust the headlight using the adjusting screw on the backsi...

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