Arctic Cat ZR 6000 R CROSS COUNTRY Operator'S Manual Download Page 12

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Rebuildable Shock Tools

Required

Optional Front Arm

Shock Springs

* Stock Spring

P/N

Tool

0744-020 Inflation Needle

0644-486 Gas Shock Retaining Blocks

0644-544 Replacement Needle

0644-169 Piston Location Tool

0644-151 Nitrogen Regulator

0644-268 Bearing Cap Seal Protector

0644-403 Bearing Cap Seal Protector (1/2-in. O.D. x 3/8 in. I.D.)

0644-404 Bearing Cap Seal Protector (5/8-in. O.D. x 3/8 in. I.D.)

0644-542 Bearing Cap Seal Protector (5/8 in. O.D. x 1/2 in. I.D.)

0644-543 Gas Shock Shaft Clamping Tool

0644-350 Floating Piston Location Gauge

0644-539 Inflation Needle Replacement Tip

0744-072 Float Shock Spanner Wrench

0644-584 Air Sleeve Bushing Installation Tool

0644-585 Air Sleeve Bushing Installation Tool

0644-456 Bullet Air Sleeve Bushing Installation Tool

P/N

Length (Inches)

2704-755*

100/250

7.75

2704-228

100/250

7.75

2704-229

160/260

7.75

1704-819

230

7.50

1704-820

170

7.50

1704-821

190

7.50

1704-822

210

7.50

1704-831

250

7.50

Ice Racing Springs

2704-749

2704-750

2704-751

110

Summary of Contents for ZR 6000 R CROSS COUNTRY

Page 1: ...O P E R A T O R S M A N U A L www arcticcat com ZR 6000 R CROSS COUNTRY...

Page 2: ...snow conditions without proper lubrication or additional idler wheels and the following parts Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured Upholstery Wear Bars Brake Pads Spark Plu...

Page 3: ...n storage instructions If major repair or service is ever required contact an authorized Arctic Cat Snowmobile dealer for professional ser vice At the time of publication all information and illustrat...

Page 4: ...____________ Your Arctic Cat Dealer ________________________ Address ____________________________________ Phone _____________________________________ WARNING This snowmobile is a very high performance...

Page 5: ...ing Skis 17 Sway Bar 18 Brake System 18 Ski Alignment 18 Recommended Gasoline 20 Preoperation Checks 20 Checking Headlight Aim 20 Track Tension Track Alignment 21 Test Ride 22 General Information 23 2...

Page 6: ...e ft lb Drive Clutch Engine 51 Drive Clutch Cover Movable Sheave 120 in lb Cam Arm Pin Lock Nut Cam Arm Pin 11 Cam Arm Set Screw Cam Arm 19 in lb Driven Clutch Driven Shaft 20 Movable Sheave Torque Br...

Page 7: ...106 1 4 5 4 29 39 4 54 73 4 79 107 4 5 6 8 30 40 8 55 74 8 80 108 8 6 8 2 31 42 2 56 76 2 81 110 2 7 9 5 32 43 5 57 77 5 82 111 5 8 10 9 33 44 9 58 78 9 83 112 9 9 12 2 34 46 2 59 80 2 84 114 2 10 13...

Page 8: ...erature 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...

Page 9: ...um 143 lb 286 lb Pink 0646 367 143 lb 250 lb Black HEAVY 0646 684 158 lb 285 lb Black 0646 410 165 lb 310 lb Black Blue DRIVEN CLUTCH Torque Bracket Degree Spring Color Spring Rate 0648 779 58 46 36 5...

Page 10: ...nce Calibrations NOTE The following table should be used as a guide only NOTE The above gearing options are combinations which allow acceptable chain tension Any other combinations will not allow acce...

Page 11: ...3 WIDE 19 SPLINE 1702 406 SPROCKET 40T TOS ASSY 1702 405 SPROCKET 49T TOS ASSY Part Number Chain 2602 369 CHAIN REXNORD 84P 13 WIDE 2062 514 CHAIN REXNORD 86P 13 WIDE 2602 370 CHAIN REXNORD 90P 13 WID...

Page 12: ...4 542 Bearing Cap Seal Protector 5 8 in O D x 1 2 in I D 0644 543 Gas Shock Shaft Clamping Tool 0644 350 Floating Piston Location Gauge 0644 539 Inflation Needle Replacement Tip 0744 072 Float Shock S...

Page 13: ...x 0 010 in 1 000 x 0 010 in 0 900 x 0 010 in Piston Orifice 0 059 in Piston Depth 2 50 in 1 125 x 0 093 in Top out Compression CD Piston 0 700 x 0 010 in 0 700 x 0 010 in 0 600 x 0 010 in 0 500 x 0 00...

Page 14: ...e 1 300 OD X 0 377 ID X 0 008 TH 0603 350 Valve 1 300 OD X 0 377 ID X 0 010 TH 0603 891 Valve 1 300 OD X 0 377 ID X 0 012 TH 0603 890 Valve 1 300 OD X 0 377 ID X 0 015 TH AC PN Description 2604 647 Va...

Page 15: ...X 502 ID 012 THK 3603 479 Valve SB 4 PORT 1 60 OD X 502 ID 015 THK 3603 480 Valve SB 4 PORT 1 60 OD X 502 ID 020 THK 8ths 16ths 32nds 64ths 64ths cont 1 8 125 1 16 0625 1 32 03125 1 64 015625 33 64 5...

Page 16: ...3 90551 73 2 87401 24 00945 74 02913 24 94488 74 2 91338 25 00984 75 02953 25 98425 75 2 95275 26 01024 76 02992 26 1 02362 76 2 99212 27 01063 77 03032 27 1 06299 77 3 03149 28 01102 78 03071 28 1 10...

Page 17: ...13 Wiring Diagram Hood Harness p n 1686 706 Cross Country 0748 009...

Page 18: ...14 NOTES...

Page 19: ...Wiring Diagram Ignition Main Harness p n 1686 732 0747 813 15...

Page 20: ...16...

Page 21: ...O 490 3 Secure the windshield using the screws according to the illustration Installing Spindle A Arm 746 483A 1 Install the A arms onto the spindle and secure using new lock nuts Tighten to 45 ft lb...

Page 22: ...screws 3 Tighten machine screws evenly to 8 ft lb 4 Position the sway bar link onto the lower A arm and the sway bar Install the cap screws and lock nuts Tighten the lock nuts to 23 ft lb Brake Syste...

Page 23: ...distance from the straightedge to the right side ski edge in two places 35 5 38 1 cm 14 15 in in front of the spindle and 35 5 38 1 cm 14 15 in behind the spindle Record the mea surements taken for t...

Page 24: ...me may choose to pre mix the first tank and if this is the case a pre mix ratio of 100 1 is acceptable A pre mix ratio of 100 1 combined with the richer fuel oil delivered from the electronic oil pump...

Page 25: ...k clip Compare the measurement with the chart 0744 068 3 Using Axle Nut Spanner Wrench p n 0644 558 from the tool kit loosen the right side rear axle nut 0744 067 NOTE Always loosen the right side rea...

Page 26: ...g track alignment 11 Loosen the right side rear axle nut just enough to apply blue Loctite 243 to the axle threads then tighten the nut to 40 45 ft lb Test Ride Test ride the snowmobile 5 to 10 minute...

Page 27: ...mm NOTE The measurements must be equal and within the specifications If the measurements are within specifications no adjustment is necessary If they are not within specifications proceed to step 5 5...

Page 28: ...new one aligning the holes with the holes in the brack ets then rivet the rear bumper to both sides of the tunnel Secure the front of the bumper using the existing machine screws and nuts Exhaust Syst...

Page 29: ...t be checked If the opera tor does not feel qualified to align the clutch clutch see an authorized Arctic Cat Snowmobile dealer for this service Shock Absorbers Each shock absorber should be visibly c...

Page 30: ...arts 8 To shut off the engine either depress the emer gency stop switch to the OFF position or pull the tether switch cap off the tether switch Braking Operating a snowmobile with hydraulic brakes is...

Page 31: ...ed Arctic Cat Snowmobile dealer for this service 6 When new brake pads are installed a burnishing process is required Drive the snowmobile slowly and compress the brake lever several times until the p...

Page 32: ...to step 4 4 If oil is low add transmission lube by removing the oil fill plug 0746 471 NOTE If excessive oil deposits are observed the chain case must be serviced Also when the oil level is at the add...

Page 33: ...s I I I Inspect for wear Throttle Cable Lever I I I Inspect for proper adjustment and wear Fuel Hoses I I I Inspect for wear and pinching Replace yearly APV Cables I I I Readjust after break in period...

Page 34: ...nd resonator 3 Remove the torx screw from the driven clutch and slide the driven clutch along with the drive belt off the driven shaft Account for alignment washers PRE RACE PRACTICE CHECKLIST WHAT TO...

Page 35: ...mount bracket then remove the spar NOTE Take care to not drop the spar inserts and nuts when removing the spar 9 Using a small needle nose pliers remove the servo motor cable holder then pull the cabl...

Page 36: ...to remove the engine support plate exhaust manifold and three coolant hoses for installation on the new engine This engine sub section has been organized to show a progression for servicing of the Ar...

Page 37: ...nd account for the harness grommets CWI 074A 6 Remove the screws securing the stator to the stator plate Route the stator lead wire out of the crankcase then remove the stator assembly 7 Remove the sc...

Page 38: ...linders to the crankcase then using a soft hammer gently tap the cylinders and remove from the crankcase by lifting them straight up off their studs Account for a gasket and alignment pins CWI 012 13...

Page 39: ...nd reed valve assem blies CWI 020 CWI 081 17 Remove the four screws securing the thermostat cap then remove the cap gasket and thermostat CWI 017 NOTE For assembling purposes note that the bypass chec...

Page 40: ...ng CWI 075A CWI 023A 21 Tip the crankcase assembly up onto the water pump side then remove the black torx screw from the bot tom of the crankcase and tip down and drain the injection oil from the cent...

Page 41: ...eaning 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 42: ...Inspect the bearing areas for cracks or excessive bearing movement If evidence of excessive bearing movement is noted the crankcase must be replaced 5 Inspect the bearing dowel pins for wear 6 Inspect...

Page 43: ...shaft making sure the retaining pin hole A in the outer race of the bearing is properly positioned and will align with the retaining pin B in the crankcase IO019B REED VALVE ASSEMBLY 1 Carefully pry t...

Page 44: ...CYLINDER CLEARANCE 1 Measure the piston skirt diameter 10 mm from the bottom of the piston just below the slot Once the measurement is final lock the micrometer CWI 080 2 Position a bore gauge between...

Page 45: ...al indicator reading 0747 810 3 If runout exceeds 0 002 in at any of the checkpoints the crankshaft must be either straightened or replaced Assembling NOTE The use of new gaskets and seals is recom me...

Page 46: ...re posi tioned inward CWI 030A 8 Install the crankshaft into the upper crankcase half Be sure the alignment hole in each bearing is posi tioned over its respective retaining pin in the crank case then...

Page 47: ...16A 16 Tip the crankcase assembly up on the water pump side then pour Arctic Cat C Tec2 engine oil into the center cavity of the crankshaft until the oil is level with the shoulder of the shaft A CWI...

Page 48: ...th an oiled piston pin NOTE The indicator arrow is found on the piston dome 24 Install the new circlips so the open end is directed either up or down 25 Rotate each piston ring until the ring ends are...

Page 49: ...s to 13 ft lb then 28 ft lb using the pattern shown 0747 890 NOTE At this point install the spark plugs then install the knock sensor Tighten the sensor to 18 ft lb 31 Install the coolant inlet hose t...

Page 50: ...y at this time into the crankshaft 41 Secure the recoil cup while using the spanner wrench and tighten the three cap screws from step 39 evenly to 18 ft lb 42 Using the spanner wrench tighten the flyw...

Page 51: ...ess plug ins clean the connectors and apply Dielectric Grease to the seal then connect all harness connectors making sure all wiring and coolant hoses are routed properly as noted in removing Install...

Page 52: ...the heat shield onto the two front locating pins B then secure it to the chassis with the two screws A Tighten securely EL 001A 28 Install the resonator and secure with the springs then place the expa...

Page 53: ...pension 3 Remove all torx head screws and cap screws securing the brake disc shield to the chassis RA031A 4 Remove the pin and allen head screws securing the brake caliper halves together then remove...

Page 54: ...re the brake caliper halves using the existing two allen head screws Tighten to 25 ft lb 8 Secure the brake disc guard using the existing torx head screws and cap screws 9 Install the resonator side p...

Page 55: ...rockets on the drive shaft align the sprocket alignment marks or the sprockets won t be timed correctly 0747 018 4 Press sprockets to proper location shown in the fol lowing illustration Sprockets are...

Page 56: ...e System If the brake lever feels spongy when applied the brake system may need to be bled To bleed the brake use the following procedure 1 Remove the reservoir cover and fill the reservoir to the hig...

Page 57: ...re will allow room for the fluid from the caliper when the pistons are pushed into the caliper for installing new brake pads Replacing the cover will prevent fluid spillage 4 Using a pair of pliers pu...

Page 58: ...cold tem peratures the drive belt should be removed and warmed up to room temperature Once the drive belt is at room temperature install the drive belt Also drive belts have a break in period of appr...

Page 59: ...er Repeat this step until the clutch releases 3 Remove the drive clutch and drive belt from the engine compartment Disassembling NOTE Note the timing marks on the cover spider and movable sheave These...

Page 60: ...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 drop...

Page 61: ...cleaning solvent wash grease dirt and foreign matter off all components dry with compressed air 2 Remove any drive belt dust accumulation from the stationary sheave movable sheave and bushings using p...

Page 62: ...040 0 080 in of float is acceptable Drive Train REMOVING CHAIN CASE DRIVEN SHAFT DRIVESHAFT TRACK 1 Remove the left and right side panels hood then loosen the quarter turns securing the lower console...

Page 63: ...retaining pin and the brake disc pads then pump the brake lever 3 or 4 times then pull back and secure the lever to the handlebar using a cable tie This will keep the fluid from leaking NOTE Place an...

Page 64: ...e Suspension section 7 Install the brake shield and left side footrest Tighten the cover cap screws to 8 ft lb NOTE Remove the cable tie securing the brake lever then pump the break lever until the br...

Page 65: ...s are used for clarity purposes and are not designed to depict actual conditions 1 Rotate both adjuster screws counterclockwise to the full open position 2 Securely clamp the EVOL chamber eyelet bot t...

Page 66: ...nt of assembly lube blue present but any indication of shock oil red indi cates worn shaft seals D 7 Using a 5 64 in hex key remove the button screw from the nitrogen pellet valve E 8 Using a FOX nitr...

Page 67: ...ed set screw then remove the ball bearing and set it aside I NOTE It is advisable to use a small magnet to remove the ball bearing from the hole J 11 Using an appropriate bearing head removing tool un...

Page 68: ...Using a scribe or pick tool remove the samurai and back up seals from the air sleeve O P 15 Pour the shock oil out of the shock body then clamp the piggy back body assembly in the vise Q CAUTION Care...

Page 69: ...g tool remove the IFP from the piggy back body S 17 Remove the IFP bleed screw and set aside T 18 Using the new seals from the appropriate seal rebuild kit replace all IFP seals U V 19 Pour the shock...

Page 70: ...bly into the eyelet Tighten to 14 ft lb X Y Replacing Air Sleeve DU Bushing NOTE The DU bushing must be replaced if it is significantly worn or damaged Z 1 Using an appropriately sized IFP removing to...

Page 71: ...Place the new DU bushing partially into the air sleeve and place the installer on top of it then using the machine press press the bushing into the air sleeve FF GG 3 At this point the inside diameter...

Page 72: ...he samurai and backup seals then place them into the air sleeve JJ KK NOTE At this point apply an ample amount of petroleum grease around the inside lip of the air sleeve then set the sleeve aside LL...

Page 73: ...on band then remove the band and discard RR NOTE Care should be taken not to scratch the piston when cutting the band 4 Remove the O ring from the piston SS 5 Install a new piston O ring then using an...

Page 74: ...tie to aid in removing the main seal ZZ NOTE When installing the main seal assure that it is oriented correctly AAA Rebuilding EVOL Reservoir 1 Install a new O ring in the rebound eyelet assembly BBB...

Page 75: ...he IFP FFF 5 Replace the IFP seal then amply lubricate the IFP and place it into the reservoir GGG 6 Thread the EVOL reservoir onto the rebound eyelet then tighten to 12 ft lb Assembling Shaft Assembl...

Page 76: ...tack piston assembly be installed correctly 4 Thread the lock nut onto the shaft then tighten to 18 ft lb Set the shaft assembly aside KKK Assembling Shock Absorber 1 Securely clamp the piggy back bod...

Page 77: ...tinue topping off the res ervoir until the oil settles evenly between the reser voir and shock body 3 Rotate the LCS adjuster screw fully closed clockwise then remove the IFP bleed screw and insert th...

Page 78: ...y open counterclockwise fill the shock body with Fox High V1 Race Oil then rotate the LCS adjuster screw fully closed clockwise XXX 8 Back out the rebound adjuster on the shaft assem bly then by inser...

Page 79: ...lush with the bearing head assembly to prevent oil from spilling into the air sleeve Gently compress the IFP to purge the last air bubbles from the body out the bleed screw Make sure the shaft is full...

Page 80: ...to liberally lubricate the bearing head assembly GGGG 16 To set the IFP depth remove the bleed screw then using Floating Piston Location Gauge p n 0644 350 adjust the depth to 2 5 in Install the blee...

Page 81: ...justed for the operational needs and riding preference of the operator The rear springs influence the load carrying capability of the snowmobile and should be adjusted for the weight and riding prefer...

Page 82: ...for servicing the front arm shock absorber w piggy back reservoir NOTE Some illustrations and photographs used in the following sub sections are used for clarity purposes and are not designed to depi...

Page 83: ...e shock body FS333 7 Slowly remove the shaft assembly from the shock body and place it on a clean lint free rag or towel FS334 8 Remove the shock from the vise and pour shock oil into a proper disposa...

Page 84: ...ng a 5 8 in socket remove the damping adjuster cartridge then clean and inspect the inboard and outboard O rings FS292A NOTE At this point inspect the re flow check valve for smooth operation and for...

Page 85: ...cer Inspect and or replace the bottom out bumper if necessary FS346 Assembling 1 Place Bearing Cap Seal Protector p n 0644 268 onto the end of the shaft then apply grease to both the tool and the shaf...

Page 86: ...tion clockwise then refill the reservoir until approximately 3 4 full FS353 8 Lightly grease the IFP then slowly insert the IFP into the reservoir and press until the IFP is level along the flat end o...

Page 87: ...n clockwise 15 Fill the shock body to approximately 1 in from the top with recommended shock oil FS361 16 Install new O rings and piston strap on the piston shaft assembly and lightly grease the pisto...

Page 88: ...sembly to 35 ft lb FS367 20 Remove the IFP relief screw then set the IFP loca tion gauge to 1 9 in measured from the top end of the reservoir FS368 FS369 21 While holding the IFP with the location gau...

Page 89: ...curing the cams to the slide rail Remove the cap screw 2 Using a 1 4 in drive ratchet and extension rotate the cams to the desired position NOTE Position 1 allows for the most weight trans fer and pos...

Page 90: ...of the console over the head light assembly and press down until it snaps in place 3 Install the two screws securing the rear of the con sole to the hood Tighten only until snug 4 Place the windshield...

Page 91: ...Cat recommends that the wear strips be checked weekly and replaced as necessary Measure the wear strips at 25 4 cm 10 in intervals Wear strips must be 10 7 mm 0 42 in thick or thicker If wear strip m...

Page 92: ...ndition first deter mine if the drive belt is within specifications see Drive Belt section and replace if worn or too long Secondly always run the drive belt in the same direc tion Installing the driv...

Page 93: ...ckets and chain tensioner for wear and the chain for proper ten sion Install the chain case cover and seal then pour Arctic Cat Synthetic Chain Lube p n 5639 038 into the oil level stick filler hole a...

Page 94: ...essary Make sure all connec tions are tight 6 Inspect the entire brake system fluid level pads etc all controls headlight taillight brakelight ski alignment ski wear bars and headlight aim adjust or r...

Page 95: ...er Hi Temp Brake Fluid Recommended for Arctic Cat hydraulic brake system Product Container Size Part Number Pkg Qty Synthetic APV 2 Cycle Oil 55 gal 2639 509 1 Synthetic APV 2 Cycle Oil 1 gal 2639 511...

Page 96: ...or reconditioning Arctic Cat snow mobile engine cylinders 0644 291 Flywheel Spanner Wrench p n 0144 007 Usage Hold starter cup while removing installing fly wheel nut 0144 007 Flywheel Puller Insert p...

Page 97: ...Extractor Nut Only Medium p n 0643 075 Extractor Nut Only Large p n 0643 072 Threaded T Handle Usage Remove piston pins 0644 328 Spring Tool p n 0644 554 Usage Remove install exhaust springs 0644 554...

Page 98: ...Test Pump p n 0644 131 Usage Check components for air leaks 0644 131 Compression Tester Kit p n 0444 213 Complete Kit p n 0444 207 10 mm Adapter p n 0444 093 12 mm Adapter Usage Test cylinder compress...

Page 99: ...s 0644 404 Clutch Compressor p n 0644 420 Usage Compress and hold drive clutch in the com pressed position for changing cam arms and removing installing six post drive clutch 0644 420 Drive Clutch Pul...

Page 100: ...Deep Socket 1 7 16 in Usage Disassemble assemble remove spider on Arctic drive clutches 0644 449 Track Clip Installation Tool p n 0644 194 Usage Install track clips on Camoplast and Yokohama rubber tr...

Page 101: ...stall skid frame idler wheels 0644 570 Floating Piston Location Gauge p n 0644 350 Usage Precisely locate and measure floating piston depth without use of a calipers 0644 350 Gas Shock Retaining Block...

Page 102: ...hock absorbers 0644 539 Nitrogen Regulator p n 0644 151 Usage Recharge rebuildable gas shock absorbers 0644 151 Piston Location Tool p n 0644 169 Usage Precisely locate the floating piston in the rebu...

Page 103: ...sconnect Coupler p n 0644 308 remove and install bolts and screws 0644 316 Insert Holder 5 16 in p n 0644 315 Usage With Torx Bit Insert p n 0644 314 remove and install torx head screws 0644 315 Phill...

Page 104: ...ch p n 0644 566 Usage Remove install a toggle switch on 2010 2012 Sno Pro 600 0644 566 Rivnut Tool Insert Bit p n 0644 233 1 4 x 20 p n 0644 405 10 32 p n 0644 430 5 16 x 18 p n 0644 431 3 8 x 16 Usag...

Page 105: ...n Hex Drive p n 0644 314 Usage With Insert Holder p n 0644 315 remove and install torx head screws 0644 314 Torx Bits 1 4 in Hex Drive p n 0644 312 25 p n 0644 393 27 p n 0644 215 30 p n 0644 313 40 U...

Page 106: ...102 NOTES...

Page 107: ...ile Division Application of council directives Issued by European Commission EMC Directive 2004 108 EC EC Machinery Directive 2006 42 EC Type of Equipment Snowmobile Brand Name Arctic Cat Model Number...

Page 108: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 495 Phone 218 681 9851 U S 204 982 1656 Canada TM...

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Arctic Cat ZR 6000 R CROSS COUNTRY, Operator'S Manual

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