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Arctic Cat Z Series 2006, Operator'S Manual

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Arctic Cat Z Series 2006 Operator'S Manual Download Page 63

62

MAINTENANCE

Removing Drive Belt (Standard 
Driven Pulley)

1. Turn ignition key to the OFF

position and wait for all moving

parts to stop.

2. Set the brake lever lock.
3. Open the hood; then open the

belt guard.

0739-613

737-316A

4. Grasp the driven pulley roller

plate and push against it while

rotating it clockwise.

5. When the sheaves are fully

apart, hold the roller plate, pull

up on drive belt, and roll the

belt over the stationary sheave

until it is free of the driven pul-

ley. Slowly release the roller

plate.

731-659A

737-317A

6. When the belt is free of driven

pulley, remove the belt from the

drive clutch.

Installing Drive Belt (Standard 
Driven Pulley)

1. Place the belt (so the part num-

ber can be read) between the

sheaves of the drive clutch.

2. Grasp the driven pulley roller

plate and push against it while

rotating it clockwise.

3. When the sheaves are fully

apart, hold the roller plate, roll

the belt over the stationary

sheave, and slowly release the

roller plate.

Summary of Contents for Z Series 2006

Page 1: ...2006 Snowmobile Operator s Manual p n 2257 327...

Page 2: ...IX 6 MONTHS from date of sale for batteries on a full exchange basis and 50 exchange for the remaining SIX 6 MONTHS of the first year 4 THIRTY 30 DAYS from date of sale for all dealer installed parts...

Page 3: ...e Models 31 Varying Altitude Operation 33 Lubrication 34 37 Standard Chain Case 34 ACT Drive Gear Case 35 Front Suspension 36 Speedometer Drive Adapter 36 Rear Suspension 36 Maintenance 38 78 Periodic...

Page 4: ...ARTS OIL AND ACCESSORIES Only genuine Arctic Cat parts oil and accessories are engineered to meet the standards and requirements of your Arctic Cat Snowmobile For a complete list of accessories refer...

Page 5: ...o warranty will be allowed by Arctic Cat Inc if the engine serial number or VIN is removed or mutilated in any way Always provide the snowmobile name VIN and ESN when contact ing an authorized Arctic...

Page 6: ...it has been upside down at all return the snowmobile to the upright position and use the following procedure CAUTION The Firecat Sabercat models should not be tipped on their right sides for any exten...

Page 7: ...gs spark plug wires air intake silencer and the engine to air intake silencer hose NOTE The engine should now be safe to operate GASOLINE OIL Recommended Gasoline Carbureted Models The recommended gas...

Page 8: ...d models or Arctic Cat Synthetic APV 2 Cycle Oil for APV models These oils are specially formulated to be used either as an injection oil or as a pre mix oil for break in and meets all of the lubricat...

Page 9: ...l 6 U S gal gaso line container for mixing the gaso line and oil To properly mix the fuel at a 100 1 ratio use the following procedure 1 Pour gasoline into the gasoline container until approximately h...

Page 10: ...eration careful adherence to the following break in guidelines will be benefi cial With occasional full throttle operation To ensure proper engine break in on standard models Arctic Cat recom mends th...

Page 11: ...gine will automatically shut off If oil pressure is lost use the follow ing procedure 1 Check the oil level NOTE To ensure an accurate reading the snowmobile should be on level ground 2 If the oil lev...

Page 12: ...If the Check Engine Light illuminates take the snowmo bile to an authorized Arctic Cat Snowmobile dealer for service If not under warranty this service is at the discretion and expense of the snowmob...

Page 13: ...Immediately shut off the engine and determine the nature of the problem see Exhaust Controlled Timing ECT System in this man ual The High Temperature Warning Light is designed to alert the snow mobile...

Page 14: ...ing the handlebar caps and block to the steering post 0734 406 2 Adjust the handlebar up or down to operator s desired tilt then tighten the lock nuts evenly and securely Check steering for maximum r...

Page 15: ...engine is run severe engine damage will result AIR INTAKE SILENCER Used in conjunction with the fuel intake system is a specially designed air intake silencer The purpose of the silencer is to quiet...

Page 16: ...ately 51 mm 2 in below the filler neck on 2 stroke models or to just below the FULL mark on 660 cc models NOTE The 660 cc models are equipped with a coolant bleed screw on the purge tank located on th...

Page 17: ...s service If not under warranty this service is at the dis cretion and expense of the snowmo bile owner DRIVE CHAIN TENSION Adjustable System The drive chain must be properly tensioned for proper oper...

Page 18: ...the OPEN position before attempt ing to start the engine NOTE On all remaining mod els there is an automatic shut off valve incorporated into the fuel pump which prevents gasoline flow when the engine...

Page 19: ...xcessive replacement is not necessary DEEP LUG TRACK Sno Pro Models The Sno Pro models are equipped with a deep lug track which is spe cially designed for use in powder snow riding conditions When the...

Page 20: ...f track studs i e small number of track studs short length of carbide many track studs long length of carbide The proper proportion between the num ber of studs and carbide length on the wear bar will...

Page 21: ...d position then apply slight throttle until positive engagement of the shift has been observed 737 831A No special maintenance is required for the reverse transmission how ever if chattering is experi...

Page 22: ...est in the forward posi tion 2 Pull back on the seat latch han dle located at the bottom rear of the seat 3 Lift on the back of the seat and move it rearward to remove it from the tunnel 0735 854 To i...

Page 23: ...ace on the locking pins 3 On the Sabercat install the rear storage compartment ARCTIC POWER VALVE APV SYSTEM This RPM controlled servomotor servo actuated system adjusts the size of the exhaust ports...

Page 24: ...s not feel qualified take the snowmobile to an authorized Arctic Cat Snow mobile dealer for this service This service is at the discretion and expense of the snowmobile owner To adjust the APV System...

Page 25: ...e jam nut securely 7 Install the actuating cables to the servo then install the servo cover EXHAUST CONTROLLED TIMING ECT SYSTEM Firecat 500 This system automatically adjusts the ignition timing to pr...

Page 26: ...st 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 f...

Page 27: ...rectly Make sure all lights are clean to provide maximum illumination The headlight and tail light must be clean and must be illu minated whenever the engine is running NOTE If equipped with reverse m...

Page 28: ...ne move the choke lever to the full choke position If the engine is warm choking is nor mally not necessary 0725 001 NOTE On carbureted models when the engine is being started with aid of the choke DO...

Page 29: ...throttle control lever compres sion may be necessary after the engine starts and during warm up Idle the engine several min utes until the engine has reached normal operating tem perature 9 On EFI mod...

Page 30: ...0 cc models ensure that the ignition switch key is in the OFF position when the engine is not running Leav ing the ignition switch in the ON position allows the lights to be on and will drain power fr...

Page 31: ...ods exceeding 5 minutes NEVER OPERATE THE SNOWMOBILE WITH THE BRAKE LEVER LOCK ENGAGED 5 Pumping the brake lever is per missible however if pumping the brake lever more than twice is necessary to obta...

Page 32: ...ere is some other malfunction of the throttle system resulting in a loss of return spring force the monitor switch will stop the engine when the throttle control lever is released If the snowmobile en...

Page 33: ...rted dis connect the throttle control wiring harness located below the han dlebar pad and next to the steer ing post If disconnection of the throttle control wiring harness is needed to start the engi...

Page 34: ...titudes Always consult the altitude decal beneath the hood of the snowmobile Crossfire M Series and King Cat models are initially set up at the fac tory for operation between 6000 9000 feet NOTE Carbu...

Page 35: ...back into the chain case with reverse Remove the oil level stick again and check the lubricant level 728 948A 0737 715 3 If the lubricant level is above the ADD mark without reverse or above the LOW m...

Page 36: ...t the finish on the hood and belly pan NOTE It is recommended that the gas tank be nearly empty less than 1 4 full when tipping the snowmobile 3 Secure the snowmobile in this position 4 Pour the exact...

Page 37: ...directly above the forward part of the upper A arm until grease is noted coming out of the bottom of the shaft Wipe excess grease from the shaft 0737 294 SPEEDOMETER DRIVE ADAPTER Semi Annually NOTE A...

Page 38: ...models should not be tipped on their right sides for any extended period of time as air bubbles may form in the oil hose If air bubbles form in the oil hose the oil injection system must be bled Take...

Page 39: ...and routing Drive Belt Daily Monthly Page 61 Check for wear cracks and fraying Check length and width dimensions Ski Wear Bars Daily Page 74 Check for wear and damage Carburetors Main Jets Adjustment...

Page 40: ...nsmit the amount of gasoline required If the in line fuel filter is obstructed gasoline flow will be restricted therefore the filter must be replaced To remove and install the in line fuel filter use...

Page 41: ...s peri odic checking of the oil injection system synchronization The syn chronization and maintenance must be done by an authorized Arctic Cat Snowmobile dealer If not under warranty this service is a...

Page 42: ...r below the bottom mark on the oil level stick add recommended oil until the oil level is slightly below the top mark on the bot tom end of the stick NOTE It takes 800 ml 27 fl oz to raise the oil lev...

Page 43: ...e the correct carbu retor main jet for the operating temperature altitude and type of gasoline is being used see Select ing Carburetor Main Jet s sec tion Since carburetor adjustments critically affec...

Page 44: ...securing the throttle cable swivel adapter then rotate the swivel adapter clockwise until the piston valve bottoms in the piston valve bore 3 Place a finger lightly against the side of the valve then...

Page 45: ...carburetors have been cali brated at the factory for average riding conditions however alti tude temperature and general wear may necessitate certain carburetor adjustments Be sure the correct carbure...

Page 46: ...oke cable adjuster once again clockwise while checking the choke cable lever for free play Adjust until 3 mm 1 8 in free play between front bottom edge of lever and housing is attained Securely tighte...

Page 47: ...ch is lifting first clockwise just enough to syn chronize the valves Recheck by repeating steps 4 7 8 With the piston valves synchro nized tighten the swivel adapter jam nuts securely Slide the rubber...

Page 48: ...ver tool tray assembly 5 With the snowmobile on a shielded safety stand start the engine release the brake lever lock and thoroughly warm up NOTE Make engine idle adjust ment only after the engine has...

Page 49: ...wner if qualified to do so If the owner does not feel qualified take the snowmobile to an authorized Arc tic Cat Snowmobile dealer for this service This service is at the dis cretion and expense of th...

Page 50: ...tes 6 After the engine has been thor oughly warmed up fine tune the idle speed screw until the engine idles smoothly NOTE If a tachometer is being used engine idle speed should be approximately 1500 R...

Page 51: ...owmo bile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for this service This ser vice is at the discretion and ex...

Page 52: ...Using the main jet wrench from the tool kit thread the main jet out of each carburetor Account for the washer Install each new main jet and the exist ing washer Tighten the main jet securely 0734 280...

Page 53: ...der normal driving conditions remove the spark plugs and exam ine the condition of the center elec trode insulator of each spark plug AO352A A TAN or LIGHT BROWN insulator indicates correct spark plug...

Page 54: ...an authorized Arctic Cat Snowmobile dealer for inspection and service If not under warranty this service is at the discretion and expense of the snowmobile owner WARNING Battery acid is harmful if it...

Page 55: ...harged the bat tery can be left connected to the charger indefinitely 3 Place the battery into position in the snowmobile and secure 4 Connect cables to the proper terminals positive cable to the posi...

Page 56: ...ent near the battery for standard mod els or behind the intake mani fold for Turbo models NOTE There is a fuse pulling tool along with spare fuses inside the fuse panel AO352A 2 Remove the suspected f...

Page 57: ...thin specifi cations adjust the brake lever travel Adjusting Brake Lever Travel 1 To decrease brake lever travel set up brakes pull out on the brake adjustment knob and rotate the knob clockwise As yo...

Page 58: ...ing the engine The brake fluid must be maintained at a level just below the high mark on the fluid res ervoir Checking Adding Brake Fluid 1 With the fluid reservoir sight glass reservoir in a level po...

Page 59: ...ile dealer for this service This service is at the discretion and expense of the snow mobile owner Checking Brake Lever Travel Before each use check the brake lever travel using the following pro cedu...

Page 60: ...at Snowmobile dealer for this service This service is at the dis cretion and expense of the snow mobile owner 1 Remove the reservoir cover and fill the reservoir to the high mark with Arctic Cat appro...

Page 61: ...oes not feel qualified take the snowmobile to an autho rized Arctic Cat Snowmobile dealer for this service This ser vice is at the discretion and expense of the snowmobile owner NOTE When installing n...

Page 62: ...cks at least once a month under normal usage of two drive belt specifications are essential 1 Measure the outside circumfer ence of the drive belt The belt should be within the recom mended range in c...

Page 63: ...rive belt and roll the belt over the stationary sheave until it is free of the driven pul ley Slowly release the roller plate 731 659A 737 317A 6 When the belt is free of driven pulley remove the belt...

Page 64: ...ing the spark plug wrench screwdriver and Belt Deflec tion Tool p n 0644 435 from the tool kit remove the sheave adjuster from the end of the driven pulley Account for and remove the O ring and shim w...

Page 65: ...miles of operation and once a week thereafter and adjusted according to need The track will stretch and take a set during break in Track deflection must be maintained within the recommended range Chec...

Page 66: ...en the adjusting bolts to increase the slack in the track 4 Check track alignment see Track Alignment section 5 When proper track tension is obtained tighten the adjusting bolt jam nuts against the ax...

Page 67: ...F NOTE Allow the track to coast to a stop DO NOT apply the brake because it could produce an inac curate alignment condition 4 When the track stops rotating check the relationship of the rear idler wh...

Page 68: ...nder actual conditions 5 After the field test check the alignment of the track If addi tional adjustment is necessary repeat Adjusting Track Align ment procedure SUSPENSION The suspension should be ad...

Page 69: ...air pressure in the air shocks once every month NOTE Adjusting air shocks may be done by the snowmobile owner if qualified to do so If the owner does not feel qualified take the snowmobile to an auth...

Page 70: ...rm shock spring and limiter straps are adjust able However Arctic Cat recom mends that the shock spring be maintained as loose as possible Tightening the skid frame front arm shock spring may cause im...

Page 71: ...ys rotate the cam from the lighter position to the heavier posi tion 727 720A To rotate an adjusting cam use the spark plug wrench from the tool kit Rotate the wrench until the cam is in the desired p...

Page 72: ...th spring blocks are in the same position either engaged or disengaged 0739 625 LIGHTS The correct taillight brakelight bulb is p n 0109 460 The correct head light bulbs are p n 0609 251 for the high...

Page 73: ...the base 3 Check headlight aim see Adjusting Headlight Aim in this sub section Removing Headlight Bulb 4 Bulb Style NOTE The bulb portion of the headlight is fragile HANDLE WITH CARE When replacing t...

Page 74: ...ncer plenum to the hood and remove the air silencer plenum to access the bulbs 4 Remove the bulb from the headlight housing and discon nect the wiring harness from the bulb 0740 462 Installing Headlig...

Page 75: ...iming surface 740 153A 7 On 3 bulb models adjust the headlight housing mounting screws until correct aim is obtained Shut the engine off then disengage the brake lever lock 8 On 4 bulb models adjust t...

Page 76: ...sively worn ski wear bars may result in a loss of steering control CAUTION The Laydown engine models should not be tipped on their right sides for any extended period of time as air bubbles may form i...

Page 77: ...nserts and washers NOTE Install the cap screw so the slotted nut will be located to the inside of the ski 7 Apply red Loctite 271 to the threads of the cap screw then tighten the nut to 6 2 kg m 45 ft...

Page 78: ...for repair or adjustment This service is at the discretion and expense of the snowmobile owner 5 Install the fan cover ACCESSORY BELT 660 cc Models Arctic Cat recommends that the con dition of the acc...

Page 79: ...tension bolt A and the pivot bolt B 0736 553 3 Insert a wooden pry bar such as a hammer handle between the engine and the alternator pry the alternator away from the engine and tighten the acces sory...

Page 80: ...e Finally always run the drive belt in the same direction Installing the drive belt so the part number can be read will ensure that the drive belt is always run the same direction DRIVE CLUTCH AND DRI...

Page 81: ...l the engine starts to drop in RPM Turn engine off NOTE On the Laydown engine models after step 4 pro ceed to step 9 NOTE On some standard mod els the air intake silencer is a one piece unit and the s...

Page 82: ...or proper tension Install the drain plug chain case cover and seal then pour the recommended amount of Arctic Cat Transmission Lube p n 0636 817 into the filler hole see Lubrication sec tion 14 On ACT...

Page 83: ...p the back end making sure the snow mobile is secure Loosen the track adjusting bolts to reduce track tension Cover the snow mobile with a machine cover or a heavy tarpaulin to protect it from dirt an...

Page 84: ...e all connections are tight then on 2 stroke models fill the oil injection reservoir with the rec ommended 2 cycle oil see Gas oline Oil sub section NOTE After prolonged storage of 2 stroke models Arc...

Page 85: ...models clean the engine cooling fins and vents 15 On 2 stroke models place the rear of the snowmobile on a shielded safety stand then start the engine Allow the engine to idle then using a long stiff...

Page 86: ...NOTES 85 NOTES...

Page 87: ...the standard warranty coverage and continues for 30 months or 2500 miles whichever comes first COMPONENTS COVERED The emissions warranty covers major emissions control components and emission related...

Page 88: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2257 327 TM ARCTIC CAT...

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