Arctic Cat ZR 120 Service Manual Download

Page: 1 / 62

2017

ERVICE

ANUAL

www.arcticcat.com

Summary of Contents for ZR 120

Page 1: ...2017 S SERVICE ERVICE MANUAL ANUAL www arcticcat com...

Page 2: ...Oil 24 Recoil Starter 25 Troubleshooting Engine 26 Fuel System 27 Pre Maintenance Checks 27 Carburetor 27 Throttle Cable 30 Troubleshooting Fuel System 32 Electrical System 33 Transistorized Ignition...

Page 3: ...ersonal injury or even death A CAUTION identifies unsafe practices which may result in snowmo bile related damage Follow the directive because it deals with the possibility of damaging part or parts o...

Page 4: ...g hours with a dry graphite based chain lubricant By using a dry graphite based chain lubricant dirt buildup on the drive chain will be minimized Before each lubri cation inspect the drive chain for d...

Page 5: ...or tape to route wires and cables away from hot or rotat ing parts 4 Inspect the drive chain and drive chain tightener Replace if necessary 5 Lubricate the drive chain with a dry graphite based chain...

Page 6: ...rocket 20 Drive Sprocket Bearing Chassis 15 Rear Suspension End Cap Rail 78 in lb Axle Housing Rail 20 Rear Arm Bracket 20 Rear Idler Wheel Axle 20 Cross Brace Axle Rail 20 Idler Axle Tunnel 20 Steeri...

Page 7: ...nsure all threaded areas are clean to assure an accurate torque value is achieved Torque values have a range of 20 120 ENG10 Torque control required Apply Loctite Lubricate with Arctic Cat 4 Stroke En...

Page 8: ...g End Side Clearance 0 008 0 024 Cam Lobe Height 1 048 1 052 Crank Pin Diameter min 1 102 Crank Pin Connecting Rod Clearance 0 0002 0 0008 Crankshaft Rod Journal Out of Round Taper 0 004 Crankshaft Ru...

Page 9: ...to the steering post support Account for two bearing halves two lock nuts and a bearing retainer IO059A 4 Pull the steering post up and back and then out of the lower steering post bearing 5 Remove th...

Page 10: ...front end IO062A 13 Remove the engine from the engine compartment Disassembling 1 Remove the oil drain plug and drain the oil then install the oil plug and tighten securely IO063 2 Remove the cover f...

Page 11: ...insulator block IO068 NOTE If the cylinder head will be replaced the car buretor studs may be removed by tightening the two nuts against each other then using a wrench on the inside nut remove the st...

Page 12: ...nd the location of the two dowel pins IO073 15 Remove the nut securing the flywheel to the crank shaft and starter pulley IO069B 16 Using a flywheel puller remove the flywheel IO074 17 Remove the cap...

Page 13: ...then remove the crankshaft NOTE For assembling purposes note the arrow mark on the dome of the piston is directed to the push rod opening of the cylinder 24 Remove the hairpin clip from the governor...

Page 14: ...7 Measuring Valve Stem Runout 1 Support each valve stem end with V Blocks then check the valve stem runout using a dial indicator ATV 1082 2 Maximum runout must not exceed 0 0004 for both valves Measu...

Page 15: ...loss of power Whether or not a valve spring is weak can be determined by its free length GM128D 2 Minimum valve spring free length must not exceed 1 04 NOTE With the crankshaft at top dead center on...

Page 16: ...sure to position the ring with its tapered side up Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cyl inder Use the piston to position each ring squarely...

Page 17: ...Take two measurements to ensure accuracy 2 Piston pin bore must not exceed 0 433 ATV 1069 CYLINDER CYLINDER HEAD NOTE If the cylinder cylinder head assembly can not be trued they must be replaced Cle...

Page 18: ...ers after honing using detergent soap and hot water and dry with com pressed air then immediately apply oil to the cylinder bores If a bore is severely damaged or gouged the cylinder must be replaced...

Page 19: ...t the case then press the bearings out of the case NOTE Thoroughly clean the bearing areas of the crankcase and crankcase cover and inspect for any nicks or imperfections of the bearing bosses of the...

Page 20: ...TE Coat the cylinder wall connecting rod bear ing surface and the crankshaft with engine oil 2 Install the crankshaft into the crankcase then with the piston rings properly oriented end gap 120 apart...

Page 21: ...mshaft IO078A 7 Install the washer onto the governor control shaft and slide the shaft up into position from inside the crank case far enough to install the hairpin clip IO101 NOTE When installing the...

Page 22: ...adjust ment nut tighten the rocker arm lock nuts to 88 in lb Verify valve clearance is 0 004 14 Install the air shroud to the cylinder head and secure the shroud with cap screw Tighten to 96 in lb IO...

Page 23: ...of the coil then repeat the procedure for the other cap screw when an air gap of 0 015 0 023 is obtained Tighten the coil cap screws to 120 in lb 22 Install the recoil starter fan housing assembly wit...

Page 24: ...Place the engine assembly into position in the engine compartment 2 On the left hand side of the engine install the three cap screws coated with blue Loctite 243 securing the engine and brake bracket...

Page 25: ...wiring harness to the main wiring harness then secure the wiring harnesses with a cable tie 16 Connect the fuel hose to the carburetor then turn the gas tank shut off valve to the OPEN position Changi...

Page 26: ...pect the loop of the spring for wear or cracking NOTE Note the orientation of the spring for assem bling purposes 2 Inspect the flat areas of the reel for wear ASSEMBLING INSTALLING 1 Install the reel...

Page 27: ...e snowmobile and hold throttle full open 5 Clean tank and entire fuel system Problem Engine Does Not Idle Condition Remedy 1 Throttle stop screw turned out too far 2 Idle fuel adjuster screw out of ad...

Page 28: ...air cleaner cover to the air cleaner case and account for the filter and retaining plate 2 Remove the flanged nuts securing the air cleaner assembly to the carburetor and engine 3 Remove the air clea...

Page 29: ...ttern over the entire sealing area A739 8 Inspect the condition of the throttle return spring CHECKING FLOAT HEIGHT 1 Remove the cap screw securing the float chamber then remove the float chamber from...

Page 30: ...titude temperature and general wear may necessitate certain carburetor adjustments Since carburetor adjustments critically affect engine per formance three external adjustments can be made on the carb...

Page 31: ...lip securing the lever pin in the throt tle lever then remove the pin and the lever A979 2 Disconnect the throttle cable from the lever then slide the cable out of the lever A980 3 Remove the C clip s...

Page 32: ...with a C clip A981 2 Seat the cable drum into the throttle lever recess then secure the throttle lever to the throttle control with a pin and C clip A980 3 Place the throttle cable into the throttle c...

Page 33: ...jet float Problem Carburetor Too Lean 0 1 4 Opening Condition Remedy 1 Choke valve hanging open 2 Pilot jet outlet obstructed 3 Float needle jet obstructed damaged adjusted incor rectly 1 Adjust serv...

Page 34: ...eel turns further the terminal voltage of the resistor r2 in the resistor circuit r1 r2 rises to the level of working voltage of the transistor TR2 when the ignition timing approaches the rated RPM an...

Page 35: ...ifications SPARK PLUG CAP 1 Remove the spark plug cap from the high tension lead by rotating it counterclockwise 2 Set the selector in the OHMS position 3 Connect one tester lead to one end of the cap...

Page 36: ...nd latch the hood Testing Handlebar Warmer Switch 1 Open the hood then disconnect the main harness wires from the switch 2 With the handwarmer toggle in the OFF position connect one ohmmeter lead to p...

Page 37: ...lever IO118A 5 Remove the retaining ring A securing the brake band Account for a washer then loosen the rear brake cable adjustment jam nut B and slide the cable out of the brake bracket Set the band...

Page 38: ...the exhaust gasket into position on the engine exhaust studs 6 Place the muffler into position in the engine com partment then press down on the muffler and posi tion the flange onto the engine exhau...

Page 39: ...NSTALLING 742 425A 1 Tip the snowmobile on its side then place the track into position in the tunnel A022 2 Slide the driveshaft assembly into position in the tun nel then secure the drive sprocket be...

Page 40: ...e track 4 If the distance between the bottom of the wear strip and the inside surface of the track is less than speci fied loosen the adjusting bolts to increase the slack in the track 5 Check track a...

Page 41: ...gnment is obtained NOTE Make sure correct track tension is main tained after adjusting track alignment see TRACK TENSION sub section 3 After proper track alignment is obtained tighten both the adjusti...

Page 42: ...nd or wear NOTE The brake band pad material thickness must be at least 1 16 or replacement is necessary 9 Inspect the brake cable for damage or fraying INSTALLING 1 Route the cable through the slot in...

Page 43: ...ut When the dis tance is within the specified range of 1 4 1 2 tighten the rearward jam nut to secure the adjustment 4 Install the clutch shield Troubleshooting Track Problem Track Edge Frayed Drive L...

Page 44: ...43...

Page 45: ...er of gravity is transferred for ward putting the required pressure onto the skis and reducing the pressure on the rear suspension position C This is essentially what weight transfer is all about the...

Page 46: ...wear strip with openings windows in the track and drive it forward onto the slide rail Secure with the machine screw and lock nut 1 With the skid frame removed remove the machine screw and lock nut s...

Page 47: ...cessive wear cracks or imperfections ASSEMBLING 1 Apply a light coat of grease to the axles and the bush ing areas 2 Place the rear arm into position on the support bracket and rail then secure with c...

Page 48: ...2 Rotate the idler wheel bearing by hand and inspect for binding or roughness 3 Inspect the axle and spacers for cracks or bends INSTALLING 1 Lightly grease the axle then slide the inner spacer onto t...

Page 49: ...cracks or unusual bends 2 Inspect the wear strip for wear The wear strip must be 0 42 thick or thicker If the wear strip measure ment is less than specified replacement of both wear strips is necessar...

Page 50: ...a 45 angle to the bottom of the tunnel 4 Align the rear idler axle with the appropriate mount ing holes in the tunnel Secure the axle to the tunnel with the cap screws coated with blue Loctite 243 Th...

Page 51: ...tainer and bearing IO059A 10 Pull the steering post up and out of the lower bearing 11 Remove the lock nuts and cap screws securing the tie rods to the steering post IO060A NOTE Use an additional wren...

Page 52: ...al times to ensure free movement 6 Apply Handlebar Adhesive to the bore of the handle bar grip then using a rubber hammer drive the grip into position 7 Place the emergency stop switch onto the right...

Page 53: ...terrain where the snow cover is minimal the ski wear bar will wear faster Arctic Cat recommends that the ski wear bars be checked once a week and replaced if worn to 1 2 of original diameter REMOVING...

Page 54: ...can only be installed on one end of the tie rod The right hand thread is the inside ball joint and jam nut 2 Secure the inner tie rod to the steering post with washers and lock nuts coated with green...

Page 55: ...le If the movement remains rough replace the spindle NOTE When greasing the spindle use enough so it can be seen coming out at both the top and bottom of the spindle 5 Inspect the spindle axle for wea...

Page 56: ...ue Loctite 243 to the jam nut threaded areas and tighten each jam nut securely against the tie rod Front Suspension A Arms REMOVING 1 Position the front of the snowmobile up onto a safety stand 2 Remo...

Page 57: ...INSTALLING 1 Using the shock spring tool place the spring on the shock absorber and secure with the retainer 2 Install the bushings sleeves and spacers into each shock end then place the shock absorbe...

Page 58: ...ght from the main wiring harness 10 Remove the seat assembly NOTE If necessary use a sharp tool to pry out all staples securing the seat cover to the plastic seat base then remove the cover from the s...

Page 59: ...glass is touched it must be cleaned with a dry cloth before installing 1 Peel back the rubber headlight socket cap then push in and turn the headlight socket counterclockwise and remove it from the he...

Page 60: ...59 Wiring Diagram 0750 506...

Page 61: ...60 NOTES...

Page 62: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2261 697...

Search results

Summary of Contents for ZR 120

Reviews:

Related manuals for ZR 120

Brands by name

Popular brands

Arctic Cat ZR 120, Service Manual

Search results

Summary of Contents for ZR 120

Reviews:

Related manuals for ZR 120

Brands by name

Popular brands