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Arctic Cat ZR 6000 R SNOCROSS 2015, Operator'S Manual

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Arctic Cat ZR 6000 R SNOCROSS 2015 Operator'S Manual Download Page 114

110

Genuine Arctic Cat 

Products

Arctic Cat Oil

- Developed, tested, and proven espe-

cially for Arctic Cat Snowmobile engines. Arctic Cat
Oil is the only oil authorized by Suzuki and Arctic Cat
engineers for use in Arctic Cat Snowmobile engines.

Arctic Cat Oil ensures warranty coverage for lubricat-

ing related incidents. Arctic Cat Oil comes in strong,
handy, recloseable containers.

Transmission Lube

- A special formula that reduces

friction and fights corrosion. Arctic Cat Transmission
Lube comes in easy-pour, recloseable containers.

Synthetic Chain Lube

- A special formula reduces

friction and fights chain case corrosion.

Fuel Stabilizer

- Fuel treatment for storage longer

than 60 days. Slows oxidation to prevent gum and var-
nish buildup. Engines start easily even after storage
periods exceeding one year. Ideal for use in snowmo-
bile gas tanks.

Antifreeze

- Pre-mixed ready for use without adding

any water. Comes in 1 gallon container.

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

6/1 gal.

Synthetic APV 2-Cycle Oil

16 gal.

2639-510

1

Synthetic APV 2-Cycle Oil

2-1/2 gal.

2639-975

2—2-1/2 gal.

Synthetic APV 2-Cycle Oil

1 qt

2639-512

12/1 qt.

Synthetic Chain Lube

8 oz

5639-038

–

Transmission Lube

12 oz

0636-817

12/12 oz

Engine Storage Preserver

12 oz

0436-888

12/12 oz

All-Temp Grease (Lithium)

14-1/2 oz

4639-365

10/14-1/2 oz

Silicone Spray

10 oz

0636-594

12/10 oz

Shock Oil - Light (Fox Racing)

1 qt

4639-345

1 qt

Fuel Stabilizer

8 oz

0436-907

12/8 oz

Hi-Temp Brake Fluid

12 oz

0436-908

6/12 oz

Antifreeze

1 gal.

0436-909

6/1 gal.

Fuel System Cleaner

12 oz

3639-619

1

Race Fuel (116-Leaded)

16 gal.

3639-620

1

Race Fuel (116-Leaded)

55 gal.

3639-621

1

Race Fuel (110-Leaded)

16 gal.

2639-098

1

Race Fuel (110-Leaded)

55 gal.

2639-097

1

Race Fuel (110-Leaded)

16 gal.

2639-098

1

Race Fuel (110-Leaded)

55 gal.

2639-097

1

Race Fuel (116-Leaded)

16 gal.

3639-620

1

Race Fuel (116-Leaded)

55 gal.

3639-621

1

Shock Oil

1 qt

5639-240

1 qt

Summary of Contents for ZR 6000 R SNOCROSS 2015

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

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 performa...

Page 5: ...ing Headlight Aim 25 Track Tension Track Alignment 25 Handlebar Ski Alignment 26 Test Ride 28 General Information 29 33 Control Locations 29 Engine Break In 29 Diagnostic Codes Check Engine Light 29 I...

Page 6: ...5 011 mm 0 9844 0 9846 in Connecting Rod Radial Play Range 0 003 0 020 mm 0 0001 0 0008 in Crankshaft Runout t i r 0 05 mm 0 002 in Crankshaft End Play Range 0 05 0 10 mm 0 002 0 004 in CHASSIS Item S...

Page 7: ...rm 45 Track Adjuster Rail 10 Rail Brace Pad Shock 4 ENGINE Item Secured to Torque ft lb Cylinder Head Cover Cylinder 2 Steps 20 25 ft lb Cylinder Crankcase 3 Steps 14 40 ft lb Thermostat Cap Crankcase...

Page 8: ...85 115 6 11 15 36 49 61 83 86 117 12 16 3 37 50 3 62 84 3 87 118 3 13 17 7 38 51 7 63 85 7 88 119 7 14 19 39 53 64 87 89 121 15 20 4 40 54 4 65 88 4 90 122 4 16 21 8 41 55 8 66 89 8 91 123 8 17 23 1 4...

Page 9: ...F 0 192 180 16 C 61 F 1 907 2940 96 C 205 F 0 199 191 14 C 57 F 2 008 3210 94 C 201 F 0 206 202 12 C 54 F 2 109 3480 92 C 198 F 0 213 213 10 C 50 F 2 210 3750 90 C 194 F 0 220 224 8 C 46 F 2 327 4170...

Page 10: ...28 144A NOTE Measure in from the shaft end the speci fied amount when checking runout at points D and F When checking runout in the center place indi cator on center of bearing as shown at point E Max...

Page 11: ...White 160 260 0648 775 52 42 46 52 44 46 0648 702 Red Black 140 240 0648 773 70 44 32 68 48 46 0648 784 Black 155 222 0648 789 68 48 36 64 48 41 0648 790 Black Light Blue 180 260 0648 791 48 44 36 48...

Page 12: ...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 13: ...ET REX 35T FWD 13 WIDE 19 SPLINE 2602 406 SPROCKET REX 36T FWD 13 WIDE 19 SPLINE 2602 371 SPROCKET REX 37T FWD 13 WIDE 19 SPLINE 2602 372 SPROCKET REX 38T FWD 13 WIDE 19 SPLINE 2602 522 SPROCKET REX 4...

Page 14: ...iston Valves Slide Carb Size mm p n 2 5 40 6506 273 Starter Jets Jet p n Jet p n 130 6506 265 150 6506 153 135 6506 101 Jet Needles Needle p n Needle p n 9DFH12 54 6506 421 9DFH3 56 6506 186 9CFH1 56...

Page 15: ...Set 3 3 1704 382 383 1360 1700 1704 384 385 1600 2001 1704 916 917 480 960 2704 224 225 1350 1890 1704 576 577 1480 1850 2704 380 381 2082 2630 2704 382 383 1550 1928 2704 384 385 567 945 P N Suspensi...

Page 16: ...603 465 Sleeve Assembly p n 3603 290 1 300 x 0 010 in 0 800 x 0 006 in Stroke 5 80 in 1 100 x 0 012 1 125 x 0 080 in Ground 1 250 x 0 015 Ring 1 300 x 0 010 in 0 0950 x 0 050 Top Out 0 800 x 0 004 in...

Page 17: ...iston Side 2704 638 Rear Arm Shock 1 600 x 0 008 in 1 425 x 0 015 in Extended Length 14 59 in Rebuild Kit p n 2603 013 1 600 x 0 008 in 1 100 x 0 0045 in Collapsed Length 10 06 in Rebuild Kit p n 3604...

Page 18: ...lve 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...

Page 19: ...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 20: ...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 21: ...17 Wiring Diagram Hood Harness p n 1686 664 SNO 491...

Page 22: ...18 NOTES...

Page 23: ...Wiring Diagram Ignition Main Harness p n 1686 732 0747 813 19...

Page 24: ...20...

Page 25: ...e windshield using the four torx head screws 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 2 Install the steering tie rod t...

Page 26: ...sition mounting loca tion of the chassis 2 Secure the bar with the two mounting brackets four machine screws 3 Tighten machine screws evenly to 8 ft lb 4 Position the sway bar link onto the lower A ar...

Page 27: ...t deflection loosen the jam nut on the belt width adjuster on the stationary sheave 6 Using an Allen wrench adjust the set screw as needed NOTE Turning the set screw clockwise increases distance betwe...

Page 28: ...otation of the tie rod end ball joints secure the tie rod jam nuts with the tie rod ends positioned 90 from each other 0743 088 Recommended Gasoline Oil Mixing Ratio The recommended gasoline to use is...

Page 29: ...dimmer switch to the 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 ver tical mark 5 cm 2 in below the horizontal...

Page 30: ...the side of the track which has the inner track drive lugs closer to the rear idler wheel rotate the adjusting bolt clockwise 1 1 1 2 turns 10 Check track alignment and make necessary adjust ments unt...

Page 31: ...sed to adjust the alignment of either ski 1 Unlock the steering tie rod by loosening the jam nuts A NOTE The inside jam nuts are left hand thread Care should be taken to rotate them in the proper dire...

Page 32: ...ing the brake lever repeatedly until the pads just start to heat up then allow them to cool down This process stabilizes the pad mate rial and extends the life of the pads 2 Allow the engine to cool t...

Page 33: ...e adjustable timing switch is a simple adjustment dial with an indexing line This line will correspond when turned with 7 different settings As indicated on the dial the settings are 0 which represent...

Page 34: ...within a range of 35 mm 1 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 specifica...

Page 35: ...he exhaust pipe reaches the system limit the system will switch to the rev limiting function and a tone change in the engine s run quality will occur This tone change may also include more frequent en...

Page 36: ...stem see an authorized Arctic Cat Snowmobile dealer for this service When filling the cooling system use a coolant water mixture which will satisfy the coldest anticipated weather conditions of your a...

Page 37: ...ench to loosen the bolt then using the fingers adjust the bolt until it is finger tight Once the adjustment bolt becomes difficult to turn by hand the drive chain is properly tensioned DO NOT OVER TIG...

Page 38: ...er by completely com pressing and releasing it several times The lever MUST return to the idle position quickly and com pletely 4 Move the emergency stop switch to the RUN posi tion 5 Assure that the...

Page 39: ...ntil the cool down period has expired and brake lever firmness has returned 2 Be sure to maintain the brake fluid at the proper level and take care not to get any moisture in the sys tem as moisture i...

Page 40: ...ile may be brought to a stop and the effectiveness under normal conditions ITEM FUNCTION CONDITION Emergency Stop Switch interrupts ignition circuit ALL Tether Switch interrupts ignition circuit ALL B...

Page 41: ...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 42: ...tle Cable Lever I I I Inspect for proper adjustment and wear Fuel Hoses I I I Inspect for wear and pinching Replace yearly Carburetors I I I Drain float bowls often Verify calibration APV Cables I I I...

Page 43: ...ive clutch will not release sharply strike the head of the puller Repeat this step until the clutch releases Remove the drive clutch driven clutch and the drive belt 4 Remove and retain the two lock n...

Page 44: ...uretors along with the impulse hose from the crankcase Remove the carburetors NOTE At this time clamp or close off the gasline hose then secure the hoses throttle cable and wiring harness out of the w...

Page 45: ...g the four cap screws securing the mount to the crank case RA009 NOTE For assembling purposes note the loca tion of the different length cap screws and spacers Disassembling Engine NOTE It is advisabl...

Page 46: ...sensor RS018A 5 Remove the cap screw securing the stator wiring harness plate then remove the plate RS019B 6 Remove the Allen head cap screws securing the stator to the stator plate then remove the st...

Page 47: ...curing the coolant inlet hose then remove the hose from the water pump and the cylinder head RS022A 10 Remove the cap screws securing the APV assem blies to the cylinders then remove the APV assemblie...

Page 48: ...s NOTE For proper assembly keep all MAG side components and all PTO side components sepa rated Assemble them on their proper sides RS029 15 Lift the pistons clear of the connecting rods and remove the...

Page 49: ...te corners leaving the heads approximately 6 mm 1 4 in out Using a plastic tipped hammer tap on each cap screw head until the case halves separate Remove the cap screws FC034 23 Lift the bottom half o...

Page 50: ...57 only 27 Place the crankcase on the bench with the water pump side down Using the long seal driver drive the mechanical water pump seal from the crank case FC036 28 Using a pair of snap ring pliers...

Page 51: ...he exhaust ports 2 Wash the cylinders in parts cleaning solvent 3 Inspect the cylinders for pitting scoring scuffing and corrosion If marks are found repair the sur face with Ball Hone p n 0644 292 FC...

Page 52: ...ling surfaces of the crankcase halves for trueness by placing each crankcase half on the surface plate covered with 400 grit wet or dry sandpaper Using light pressure move each half in a figure eight...

Page 53: ...Remove the spark plugs from the 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...

Page 54: ...ithin specifications AC091 Piston Ring End Gap 1 Place each piston ring in the wear portion above the exhaust port of its respective cylinder Use the pis ton to position each ring squarely in each cyl...

Page 55: ...and rotate the crankshaft slowly Note the amount of crankshaft runout total indicator reading FC046 4 Position the indicator contact point against the crankshaft at point C center Zero the indicator...

Page 56: ...ump seals then remove the tool FS191 6 Position the shim on the oil injection pump end of the driveshaft RS043 7 Position the upper crankcase half upside down on two wooden blocks then install the C r...

Page 57: ...ated until it drops onto the retaining pin 11 Position the two center seal rings with their end gaps 180 apart up on one and down on the other CM036A 12 Apply a thin coat of Three Bond Sealant p n 063...

Page 58: ...ber side of the washer is directed toward the impeller Apply blue Loctite 243 to the threads of the cap screw and tighten to 96 in lb NOTE For assembling purposes it is advisable to lubricate the rubb...

Page 59: ...o clock position RS033A RS032A 23 Install the coolant temperature sensor coated with white Loctite 575 and tighten to 18 ft lb then secure the sensor wire to the sensor with a cable tie 24 With new g...

Page 60: ...lies and cylinder bores Remove the rubber bands from the connect ing rods 30 In turn on each cylinder place a piston holder or suitable substitute beneath the piston skirt and square the piston in res...

Page 61: ...e correctly posi tioned in the grooves RS052A RS026A NOTE Lubricating the cylinder O rings with a light coat of grease will help keep them seated in the grooves of the cylinder and cylinder head NOTE...

Page 62: ...h blue Loctite 243 Tighten to 8 ft lb 38 Secure the stator plate to the crankcase with the Allen head cap screws coated with blue Loctite 243 and tightened to 8 ft lb then install the stator assembly...

Page 63: ...ch exhaust port and install the exhaust gaskets with the metal sides facing out then install the exhaust manifold and secure with four flange nuts and lock washers Tighten the four nuts to 8 ft lb 45...

Page 64: ...the throttle cable and secure with the jam nuts then connect the TPS connector to the MAG side carburetor RA008 RS074A 9 Secure the air silencer boots making sure they are properly seated to the inta...

Page 65: ...sing the sheaves allowing the sheaves to fully close Verify proper drive belt deflection 743 067B 17 Install the resonator and expansion chamber and secure it to the chassis with the springs and hairp...

Page 66: ...in from the end of the fuel hose then install on the filter 4 Remove the vise grip pliers from the fuel hose Servicing Carburetors Disassembling RS002B NOTE The carburetors do not have to be removed t...

Page 67: ...pilot jet and starter jet RS005A 6 Remove the screws securing the float assembly RS007A 7 Remove the float assembly by lifting it up and out of the mixing body Account for the O ring and the needle va...

Page 68: ...be removed to free the throttle valve from the lever assembly 12 Remove the E clip securing the plate to the throttle valve then slide throttle valve to one side and remove Account for the plate washe...

Page 69: ...Inspect the carburetor mounting flanges for dam age and tightness 9 Inspect the throttle shaft seal for damage and signs of leaking Assembling 1 Place the throttle valve into the mixing body making su...

Page 70: ...en secure the float assembly with the screws NOTE It may be necessary to use a spray lubricant such as WD 40 to aid in installing the float assembly RS004 RS007A 6 Install the starter jet pilot jet an...

Page 71: ...onizing Throttle Valves 1 With the throttle in the idle position select a small drill bit that will just fit under the cutaway of the fixed throttle valve 2 Using the same drill bit check the clearanc...

Page 72: ...changed depending upon the type of gasoline you are using your operating altitude and temperature following the break in period to the proper main jets for the operating condi tions Refer to the Main...

Page 73: ...ressure pry out the retaining bar from each side of the reed cage RS010 NOTE It is necessary to pry each retaining bar until it can be removed by hand 4 Push the inner reeds free of the locating tabs...

Page 74: ...enter electrode insulator of each spark plug 0725 048 A TAN or LIGHT BROWN insulator indicates correct spark plugs heat range B LIGHT GRAY or WHITE insulator indicates overheating of the engine This c...

Page 75: ...e chain case cover Remove cover 7 Loosen the jam nut and the chain tensioner enough to remove the chain and sprockets then remove the chain and sprockets Remove chain lube oil 0747 877 RA013 8 Remove...

Page 76: ...rockets must be removed from the brake side of the track drive RA027A 1 For installing purposes scribe a line on the drive shaft A next to the drive sprocket for proper align ment then scribe a line o...

Page 77: ...e disc be checked daily for fluid leakage wear or damage and for proper operation Also the brake fluid level must be checked every time before starting the engine The brake fluid must be visible in th...

Page 78: ...p 3 until the brake fluid flows free of air bubbles NOTE It may be necessary to refill the reservoir during the bleeding process 5 When the brake fluid is free of all air and the brake lever feels fir...

Page 79: ...or cracking fraying etc If any of the specifications or conditions are unsatis factory replace the drive belt NOTE Drive belts should be purchased from an authorized Arctic Cat Snowmobile dealer as Ar...

Page 80: ...epeat 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 mus...

Page 81: ...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 82: ...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 83: ...2 With heavier springs the front end will become more aggressive in the corners as more weight will be transferred to the skis when decelerating Also more weight is transferred to the rear on accelera...

Page 84: ...ut do not remove the air sleeve B 5 Remove the shock from the vise invert it and clamp it in the vise by the reservoir eyelet 6 Unthread the air sleeve from the EVOL chamber by hand and slide it down...

Page 85: ...ogen valve for signs of wear such as holes on the face of the pellet Replace if necessary F 9 Press down on the reservoir end cap then using a scribe or a pick tool remove the reservoir snap ring Pull...

Page 86: ...shock then gently pull the piston shaft bearing EVOL free from the shock body Set this entire assembly aside L M 13 Remove the air sleeve from the reservoir end of the shock N 14 Using a scribe or pic...

Page 87: ...83 O P 15 Pour the shock oil out of the shock body then clamp the piggy back body assembly in the vise Q R 16 Using an appropriate IFP removing tool remove the IFP from the piggy back body S...

Page 88: ...r the shock oil out of the piggy back body assembly W 20 Using a 5 8 in wrench remove the LSC assembly from the eyelet thoroughly clean the assembly replace the O rings and install the assembly into t...

Page 89: ...strike the rod with a hammer freeing the bushing AA BB CC DD NOTE To install a new DU bushing an appropri ate bushing installer A sizer B and machine press must be available EE 2 Place the new DU bush...

Page 90: ...Using the machine press press the stack until the sizer falls free within the air sleeve Remove the installer and the sizer II 4 Apply an ample amount of petroleum grease to the samurai and backup se...

Page 91: ...ift the piston and valve assembly collectively off the shaft NN OO NOTE It is advisable to use cable ties to pre serve the upper and lower shim stack piston order PP QQ 3 Using a sharp blade cut the p...

Page 92: ...sing an appro priate piston band installation tool install a new band TT 6 Remove the spring from the assembly then remove the bearing assembly UU VV 7 Remove and replace all O rings and seals WW XX Y...

Page 93: ...eyelet assembly BBB 2 Remove the EVOL reservoir from the rebound eyelet assembly then install a new reservoir O ring CCC DDD 3 Using a shock absorber hand air pump apply light pres sure to the reservo...

Page 94: ...he vise install the bottom out bumper HHH 2 Place the Bearing Cap Seal Protector p n 0644 268 onto the shaft amply lubricate the protector and install the bearing assembly onto the shaft III 3 Install...

Page 95: ...2 Assuring that the LCS adjuster screw is rotated fully open counterclockwise fill the piggy back reservoir with Fox High V1 Race Oil almost to the rim OOO PPP NOTE It is normal for oil to seep throug...

Page 96: ...screw UUU NOTE It is allowable to leave some oil trapped in the reservoir above the piston 6 Using the IFP installing tool press the IFP to the bottom of the reservoir then pull the IFP back 2 in from...

Page 97: ...ess the metering rod lightly until the metering rod moves away from the jet 9 While holding the negative spring and spacer at the top of the shaft with one hand insert the shaft and bearing assembly i...

Page 98: ...urge the last air bubbles from the body out the bleed screw Make sure the shaft is fully extended to the point of it contacting the negative spring CCCC DDDD 14 Install the bleed set screw then using...

Page 99: ...bleed screw HHHH 17 Pour the excess oil from the IFP reservoir install the reservoir end cap pressing it down firmly and install the snap ring IIII JJJJ KKKK 18 Using an appropriate inflation needle...

Page 100: ...ecommends that the shock spring be adjusted to a maximum of 6 4 mm 1 4 in up or down from the standard pre load setting NOTE The standard pre load spring length installed is 7 30 in When customizing t...

Page 101: ...the reservoir end cap and remove the end cap retaining ring FS331 5 Using a 3 8 24 cap screw remove the reservoir end cap from the reservoir then discard the end cap O ring FS378 6 Loosen and unscrew...

Page 102: ...uster to the fully open position coun terclockwise FS384A 10 Using Piston Location Tool p n 0644 169 remove the IFP from the shock body Place the IFP on a clean lint free rag or towel Discard excess r...

Page 103: ...up FS343 16 Using a 9 16 in wrench remove the piston nut from the end of the shaft FS344 17 Slide the piston assembly onto a T handle wrench to preserve the shim stack piston order Remove and discard...

Page 104: ...Place the shock body and eyelet in the vise with the open end directed up 6 Fill the reservoir with Shock Oil p n 5639 240 until approximately 3 4 full NOTE Allow a few minutes for oil to overflow in...

Page 105: ...FS358 12 Using the IFP location gauge slowly stroke the IFP in the reservoir several times to purge air from between the reservoir and shock body Repeat this process until no air bubbles rise through...

Page 106: ...air is purged from the shim stack piston assembly FS363 17 Fully extend the shaft without exposing the piston to air then refill with recommended oil until approximately 1 in from the top or to where...

Page 107: ...mbly and tighten only until snug then loosen two turns 25 Insert the needle squarely into the center of the nitrogen valve set screw and plug taking care that the valve is directed away from face and...

Page 108: ...ole then remove the windshield 2 Remove the four screws securing the windshield brace to the console Disconnect the gauge then remove the windshield brace assembly 3 Disconnect the electrical accessor...

Page 109: ...the aiming 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 headli...

Page 110: ...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 mea surements are less...

Page 111: ...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 112: ...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 113: ...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 114: ...ner 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 51...

Page 115: ...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 116: ...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 117: ...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 compres...

Page 118: ...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 119: ...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 120: ...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 121: ...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 122: ...connect 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 Philli...

Page 123: ...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 124: ...in 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...

Page 125: ...e 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 Numbers...

Page 126: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 442 Phone 218 681 9851 U S 204 982 1656 Canada TM...

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