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204

FOX Air Shocks

AIR LEAKAGE POINTS



NOTE: When attaching the air pump, the hose and

gauge will fill with air from the air chamber resulting

in a lower air pressure reading than the shock was

originally set at. This is normal.

1. Check for leaks at room temperature and cold tem-

peratures. Set the shock outside overnight during the

winter months.

2. Charge the shock to 100 PSI; then fill a 5 gallon pale

of water.

3. Remove the air valve cap(s) and submerge the shock

in water. Look for air bubbles to determine if a seal

or O-ring has failed.

SNO-663

4. If service work is needed on any FOX shocks, the

shock will have to be removed and sent to FOX or

any FOX distributor for any service work. For FOX

shock information log on to www.ridefox.com.

REPLACING AIR VALVE/O-RING

1. If an air leak is detected around the air valve, remove

and discard the existing air valve and O-ring. Install

new air valve and O-ring. Tighten to 35 in-lb.

SNO-66

Servicing IFP Shock

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when servicing the rear suspension.



NOTE: Special tools are available from the Arctic

Cat Service Parts Department.



NOTE: If service work is needed on any FOX

shocks, the shock will have to be removed and sent to

FOX or any FOX distributor for any service work.

For FOX shock information log on to www.ride-

fox.com.

REMOVING/CLEANING

1. Remove the shock from the snowmobile; then

remove the spring from the shock body using the

shock spring removal tool.

2. Wash the shock body in parts-cleaning solvent.

DISASSEMBLING

1. Remove the screw from the bottom of the shock.

Discharge all the pressure from the shock using the

Inflation Needle. Open the valve in filler handle until

all pressure is released.

Description

p/n

Piston Location (IFP) Tool

0644-575

Inflation Needle Tool

0744-020

Rear Suspension Spring Tool

0144-311

Shock Body Clamping Tool

0644-486

Shock Rod Clamp Tool

0644-425

Bearing Cap Seal Protector Tool

0644-268/403/404

Shock Spring Removal Tool

0644-057

! WARNING

Before any service is performed on the gas shock
absorber, first discharge all pressure from the shock
remote reservoir. Remove the valve screw from the
pressure valve and insert the Inflation Needle. Open
valve until all pressure is released. Failure to do this
may cause personal injury.

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Содержание M 8000

Страница 1: ...www arcticcat com SERVICE MANUAL www arcticcat com...

Страница 2: ...g System Schematic 116 Recoil Starter 117 Arctic Power Valve APV System 118 Exhaust Controlled Timing ECT System 122 Fuel Systems 123 EFI System 123 Individual Components 123 Self Diagnostic System Co...

Страница 3: ...e not designed to depict actual conditions Because Arctic Cat Inc constantly refines and improves its products no retroactive obligation is incurred All materials and specifications are subject to cha...

Страница 4: ...rive belt is at room temperature install the drive belt see Drive Belt sub section in the Drive Train Track Brake Systems section of this manual Genuine Parts When replacement of parts is necessary us...

Страница 5: ...e the chance of the front end bottoming out With a stiffer spring pre load the ride of the snowmobile will improve on the trail but will affect the performance in the deep powder snow In deep powder s...

Страница 6: ...h driven clutch Lay the belt on a flat surface or slide it into a cardboard sleeve to prevent warping or distortion during storage then clean and inspect the drive clutch and driven clutch 9 Apply lig...

Страница 7: ...snubber on the torque link will all take a set during the first 100 miles allowing the distance between the drive clutch and driven clutch to shorten When this happens the snow mobile will appear to...

Страница 8: ...0 8661 0 8665 Connecting Rod Small End Bore 1 0631 1 0634 Connecting Rod Radial Play 0 0001 0 0008 Crankshaft Runout t i r 0 002 Crankshaft End Play 0 002 0 004 Reed Stopper Height 0 315 ITEM Engine N...

Страница 9: ...8 Arctic Power Valve APV System Specifications 0735 516 VALVE POSITION CYCLE RPM Mid Open Full Open 67 7500 Low High Alt 77 8500 Low High Alt APV CABLE LENGTH 6000 8000 36 5 mm 1 mm...

Страница 10: ...white green red Lighting Coil 0 08 0 12 ohm yellow yellow Ignition Timing Sensor 1 148 222 ohms green white brown green Ignition Timing Sensor 2 148 222 ohms green white brown green Fuel Injector 11...

Страница 11: ...3 0627 083 42 4600 81 8200 19T 50T 90 M 8000 6 8000 85 255 lb 68g 180 240 lb 48S ER3 0627 084 42 4600 81 8200 19T 50T 90 ALIGNMENT BAR MODEL OFFSET P N CENTER TO CENTER OFFSET FLOAT 6000 8000 0744 093...

Страница 12: ...84 108 112 115 119 122 126 129 133 136 140 143 147 150 154 157 9 Tooth 2 52 pitch 19 50 0 380 90 57 58 60 62 64 66 68 69 71 73 75 77 79 80 82 21 49 0 429 90 64 66 68 70 72 74 76 78 80 82 84 87 89 91 9...

Страница 13: ...7 130 134 137 141 144 148 151 155 159 23 36 0 639 84 113 117 121 124 128 132 135 139 143 146 150 154 157 161 165 24 35 0 686 84 122 126 130 133 137 141 145 149 153 157 161 165 169 173 177 10 Tooth 2 5...

Страница 14: ...Wire Diameter A Angle B Coil Width C Coils Length D ZR 405 90 3 65 6 75 18 50 SKI Model Collapsed Length Extended Length Stroke Piston Depth ZR XF 12 59 18 38 5 79 7 00 M SE 11 49 16 33 4 84 6 90 FRON...

Страница 15: ...Steering Arm 20 Tie Rod Spindle Arm 32 Steering Support Spar 20 Steering Support Upper Console 30 in lb Steering Arm Chassis 8 A Arm Upper XF HC M Chassis 9 A Arm Upper ZR XF Chassis 23 A Arm Lower Ch...

Страница 16: ...r then move the hood slightly forward and remove the hood 4 Disconnect the exhaust temperature sensor from the main harness then remove all springs securing the expansion chamber Remove the expansion...

Страница 17: ...Tighten evenly to 15 ft lb SNO 357 6 Install the expansion chamber using the existing springs then connect the exhaust temperature sensor to the main harness 7 Position the hood onto the snowmobile a...

Страница 18: ...teering post Discard both nuts SNO 2221A 7 Remove the torx head screw and nut securing the tie rod link to the secondary steering post then remove the two machine screws and nuts securing the top of t...

Страница 19: ...then secure the steering post using the existing retaining ring SNO 740A NOTE Verify the bushings are properly oriented the seam should be centered front to back 2 Install the adjusting block onto th...

Страница 20: ...sing the machine screw and nut Tighten to 20 ft lb 10 Install the expansion chamber using the existing springs then connect the exhaust temperature sensor to the main harness 11 Position the handlebar...

Страница 21: ...acket then remove the nut B securing the steering tie rod assembly to the steering post Discard both nuts SNO 2221A 7 Remove the torx head screw and nut B securing the tie rod link to the secondary st...

Страница 22: ...ure the assembly using existing cap screws and nuts Tighten cap screws to 23 ft lb SNO 334 2 Secure the bottom of the steering post to the lower steering support using existing thrust washer and new N...

Страница 23: ...ten evenly to 15 ft lb 0747 883 12 Install the hood and both access panels Ski ZR XF REMOVING 1 Elevate the front of the snowmobile and secure on a support stand 2 Remove and discard the cotter pin th...

Страница 24: ...ar INSTALLING 1 Slide a washer onto the cap screw used to secure the ski then apply all temperature grease to the shaft portion of the cap screw and spindle axle 2 Install the spindle axle and spacers...

Страница 25: ...o 32 ft lb 4 Install the ski 5 Turn the handlebar fully to the right and then to the left to verify the steering moves freely Spindle XF HC M 0749 480 REMOVING 1 Position the front of the snowmobile o...

Страница 26: ...e steering tie rod end to the steering arm Discard the nut SNO 350 5 Remove the lock nut securing the steering tie rod to the steering post Discard the nut SNO 351 NOTE At this point if the technician...

Страница 27: ...20 ft lb SNO 349 Ski Alignment CHECKING NOTE Track tension and alignment must be prop erly adjusted prior to checking or adjusting ski align ment Ski alignment must be performed on a flat level surfa...

Страница 28: ...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 spindle tie...

Страница 29: ...ms from the spindle Discard the nuts SNO 354 6 Remove the cap screw and lock nut securing the sway bar link to the lower arm Discard the nut XM135 7 Remove the two cap screws and nyloc nuts securing t...

Страница 30: ...rm with the cap screw and new nyloc nut Tighten to 23 ft lb XM135 4 Secure the A arms to the spindle using two new nyloc nuts Tighten to 45 ft lb 5 Install the ski shock absorber 6 Place the front ski...

Страница 31: ...ting bushings Secure with the cap screws and new lock nuts and tighten to 55 ft lb front and 45 ft lb rear PC095A 4 Secure the A arms to the spindle using one new lock nut and one new tri nut Tighten...

Страница 32: ...sway bar link to the lower A arm and the sway bar XM135 2 Remove the torx head screws securing the sway bar mounting brackets then pull the sway bar out of the snowmobile INSPECTING 1 Inspect the swa...

Страница 33: ...nt cushion material back and onto the plastic seat base Check for wrinkles and secure with staples and two screws 5 Install the seat assembly Seat Assembly M Sno Pro HCR LTD REMOVING INSTALLING 1 Remo...

Страница 34: ...lap to the rear bumper using new rivets 2 Secure the front of the bumper to the chassis using the existing machine screws and nuts Tighten securely 3 Install skid frame assembly using two existing mac...

Страница 35: ...d 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 t...

Страница 36: ...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 aimi...

Страница 37: ...ust temperature 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 driv...

Страница 38: ...he way 13 Remove the recoil starter from the engine Secure it out of the way XM252 14 Remove the cap screws securing the MAG side engine mount to the engine 15 Remove the spark plug caps from the spar...

Страница 39: ...n to 96 in lb 11 Before connecting the wiring harness plug ins clean the connectors and apply Dielectric Grease to the seal then connect all harness connectors making sure all wiring and coolant hoses...

Страница 40: ...the screws then install the hood harness Install the side access panels 27 Start the engine and warm up to operating tempera ture then verify that all components are functioning properly and that cool...

Страница 41: ...40 Assembly Schematic 4000 500CC1A12 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10...

Страница 42: ...41 500cc_2A_15...

Страница 43: ...ide the driven clutch along with the drive belt off the driven shaft Account for the offset washers 4 Using Drive Clutch Bolt Tool remove the torx head screw and high collar washer securing the drive...

Страница 44: ...move the center oil hose from the front of the engine EL 005B 16 Remove the two small oil hoses from the oil pump assembly CWI 112A 17 Loosen the clamp securing the gasline hose to the fuel rail and r...

Страница 45: ...replaced make sure to install the existing engine support plate and the exhaust manifold on the new engine Tighten the exhaust manifold nuts to 12 ft lb the M6 engine sup port plate cap screws to 25...

Страница 46: ...the cylinder head vent hose 11 Place the recoil starter into position and secure with the cap screws Tighten in a crisscross pattern to 96 in lb 12 Before connecting the wiring harness plug ins clean...

Страница 47: ...and shock mount bracket using the existing cap screws Tighten the cap screws to 25 ft lb 26 Secure the idle speed control ISC hoses A to the top of the throttle bodies using the existing clamps then c...

Страница 48: ...are functioning properly and that coolant is circulating through the cooling system properly 36 After running the engine to the proper operating tem perature shut the engine off then open the access p...

Страница 49: ...48 Assembly Schematic 6000 600_14_1 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10...

Страница 50: ...49 600_14_2...

Страница 51: ...e all springs securing the expansion chamber and resonator then remove the expansion chamber and resonator 3 Remove the cap screw and washer securing the driven clutch and slide the driven clutch alon...

Страница 52: ...ooling System the Engine Related Items section 13 Loosen the clamp securing the gasline hose to the throttle body and remove the hose then close off the hose and secure the hose up and out of the way...

Страница 53: ...p screws and carriage bolt nut securing the PTO side chassis support to the shock mount bracket and chas sis Remove the chassis support and account for the carriage bolt 24 Remove the torx head screws...

Страница 54: ...with a cable tie 13 Install the cylinder head vent hose PC178B 14 Place the recoil starter into position and secure with the cap screws Tighten in a crisscross pattern to 96 in lb 15 Before connectin...

Страница 55: ...nator with the springs NOTE When installing the manifold springs the long hook portion of the spring must be attached to the exhaust manifold or premature spring failure will result 32 Install the exh...

Страница 56: ...ant as necessary Verify the tight ening torque of the drive clutch CAUTION If the engine had a major overhaul or if any major com ponent was replaced proper engine break in proce dures must be followe...

Страница 57: ...56 Assembly Schematic 8000 800_12_1 Torque Specification Tolerances Torque ft lb Tolerance 0 15 20 16 39 15 40 10...

Страница 58: ...57 800_12_2...

Страница 59: ...ecuring 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 f...

Страница 60: ...n hose from each flange and the crankcase nozzle FC026 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 cran...

Страница 61: ...ecuring the oil injection pump to the crank case Remove the pump retainer and O ring FC031 19 Turn the engine upside down on support blocks and remove the coolant temperature sensor if neces sary FC03...

Страница 62: ...er drive the mechanical water pump seal from the crankcase FC036 26 Using a pair of snap ring pliers remove the snap ring securing the inner seal in the crankcase 27 Using the hooked end of the tool p...

Страница 63: ...spots before assembly by continuing to move the cylinder in a fig ure eight motion until a uniform bright metallic fin ish is attained PISTON ASSEMBLY 1 Using a non metallic carbon removal tool remove...

Страница 64: ...perature sensor threads coated with white Loctite 575 and tighten to 18 ft lb CRANKSHAFT NOTE If any servicing of the connecting rods cen ter bearings or oil injection pump drive gear is neces sary Ar...

Страница 65: ...n be found in Section 1 of this manual CYLINDER HEAD VOLUME Squish Gap Method To check the squish gap a micrometer and two heavy pieces of solder will be needed 1 Remove the spark plugs from the engin...

Страница 66: ...ach 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...

Страница 67: ...nt 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...

Страница 68: ...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 A...

Страница 69: ...iner 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 tool press the seal into position making sure its marked side is po...

Страница 70: ...mostat Secure the housing with cap screws and tighten to 96 in lb FC078A FC073 23 With new gaskets install the reed valve assemblies then secure the intake flanges to the crankcase Tighten in a crissc...

Страница 71: ...on each cylinder place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase then using a ring compressor or fingers compress the rings and...

Страница 72: ...0738 204 NOTE After tightening the 8 mm cap screws tighten the two remaining 6 mm cap screws to 96 in lb NOTE At this point pressure test the engine see Section 3 37 Secure the stator plate to the cra...

Страница 73: ...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 the overflow hose and...

Страница 74: ...ler or suitable substitute remove the flywheel from the crankshaft by tightening the puller bolt using an pneumatic gun Account for the key NOTE To ensure the cleanliness of the flywheel magnets place...

Страница 75: ...isconnect the coolant hose from the back of the cyl inder head 10 Remove the cap screws with O rings securing the cylinder head in the order shown then separate the head from the cylinders Account for...

Страница 76: ...he connecting rods and remove the small end connecting rod bearings then remove the piston rings Keep each piston with its rings keep each piston pin and bearing together as a set CWI 015 16 Remove th...

Страница 77: ...move the two crankcase torx screws A from the water pump side of the engine then remove the two cap screws B from the magneto housing CWI 075A CWI 023A 21 Tip the crankcase assembly up onto the water...

Страница 78: ...he mechanical water pump seal from the crankcase FC036 28 Using a pair of snap ring pliers remove the snap ring securing the inner seal in the crankcase 29 Using the hooked end of the tool pull the in...

Страница 79: ...rankcase halves for scoring pitting scuffing or any imperfections in the casting 3 Inspect all threaded areas for damaged or stripped threads 4 Inspect the bearing areas for cracks or excessive bearin...

Страница 80: ...ing 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 the reed a...

Страница 81: ...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 the mic...

Страница 82: ...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 C Tec2 engine oil 1 Apply a...

Страница 83: ...urn the engine right side up and tighten screws 12 15 in two steps to 102 in lb 13 Apply a thin coat of grease to the sealing surface of the water pump shaft then place the Oil Seal Protec tor Tool at...

Страница 84: ...the pump shaft then install the retainer with a new O ring Tighten screws to 102 in lb 19 Secure the reed valve assemblies and intake mani folds to the engine case using the existing screws Tighten i...

Страница 85: ...r O rings lightly coated with oil on the top of each cylinder making sure they are cor rectly positioned in the grooves CWI 010 30 Place new O rings lightly coated with oil onto each of the head cap s...

Страница 86: ...crews coated with blue Loctite 243 Tighten to 80 in lb then install the wiring grommet into the notch of the crankcase 38 Secure the lower ignition timing sensor and bracket with two screws coated wit...

Страница 87: ...ts Tighten the nuts in a criss cross pattern to 12 ft lb 45 If the knock sensor was removed secure it to the cyl inder head using the existing cap screw Tighten to 18 ft lb 46 After installing the eng...

Страница 88: ...remove the three starter clutch cap screws and remove the clutch CM138 CM139 2 Install the Flywheel Puller Insert onto the end of the crankshaft IO013 3 Using Flywheel Puller or suitable substitute r...

Страница 89: ...e to the engine then remove the plate CM145D NOTE For assembling purposes note the indenta tion A of the stator plate is aligned with the harness opening B in the crankcase CM145C NOTE The stator plat...

Страница 90: ...unt for gasket s and alignment pins XM018 12 Remove the PTO side piston pin circlip from the PTO side piston then remove the MAG side pis ton pin circlip from the MAG side piston XM020A 13 Using Pisto...

Страница 91: ...k 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 C...

Страница 92: ...he 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 half 25 Lift the crankshaft free fr...

Страница 93: ...scuffing and corrosion If marks are found repair the surface with the 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...

Страница 94: ...t any high spots by continuing to move the half in a figure eight motion until a uniform bright metallic finish is attained NOTE Care must be taken not to remove an exces sive amount of aluminum or th...

Страница 95: ...s replace the reed valve 4 To assemble place the reed valves on the cage with its clipped corner positioned to the lower right hand corner of the cage Place the reed stopper assembly into position and...

Страница 96: ...the crankshaft on the surface 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 a...

Страница 97: ...ner 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 position NOTE Grease must be applied to the...

Страница 98: ...rops onto the retaining 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...

Страница 99: ...on pump making sure the pump shaft slot A and pump driven gear shaft B align Secure with two screws coated with blue Loc tite 243 Tighten the two screws to 96 in lb CM167A 18 Place the lower union ass...

Страница 100: ...ated with a light coat of grease and directed toward the impeller Apply blue Loctite 243 to the threads of the cap screw and tighten to 108 in lb IO018A 24 Apply High Temp Sealant to the crankcase wat...

Страница 101: ...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 NOT...

Страница 102: ...n the top of each cylinder making sure they are correctly positioned in the grooves XM022 36 Place new O rings lightly coated with oil onto each of the head cap screws Place four of these cap screws f...

Страница 103: ...ten to 48 in lb then install the wiring grommet into the notch of the crankcase IO049A 42 Secure the lower ignition timing sensor with two cap screws A coated with blue Loctite 243 Tighten to 48 in lb...

Страница 104: ...e hose clamps securely XM023 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 hi...

Страница 105: ...pression low 11 Stator faulty Fuel pump or injector coil 12 ECM faulty 1 Fill tank 2 Replace hose 3 Remove obstruction replace vent hose 4 Remove obstruction replace pick up valve s 5 Replace regulato...

Страница 106: ...s 9 Replace bleed adjust oil injection pump 10 Replace reed petals 11 Refill coolant repair Thermostat repair Water Pump Assembly 12 Replace fuel with higher octane 13 Replace ECM CCU Problem Engine...

Страница 107: ...unt 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 eng...

Страница 108: ...nkcase 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 crank...

Страница 109: ...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 pum...

Страница 110: ...se 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 pum...

Страница 111: ...l pins CWI 016A 3 Remove the cap screw securing the impeller Account for the rubber washer and gasket behind the cap screw Remove the impeller from the shaft CWI 082 NOTE If the impeller will not slid...

Страница 112: ...self against the crankcase FS232 6 Apply a light coat of grease to the sealing surface of the pump driveshaft then install Oil Seal Protector Tool at the end of the shaft Twist the shaft while pushing...

Страница 113: ...ater pump seals must be replaced FS219A NOTE When servicing the water pump use Water Pump Bearing and Seal Tool Kit and Oil Seal Protec tor Tool 1 Loosen the clamps securing the coolant hoses to the w...

Страница 114: ...the shaft back out of the impeller 6 Remove the oil injection pump retainer and shaft from the opposite side of the crankcase Account for the shim located between the retainer and shaft flange FS226 7...

Страница 115: ...o the sealing surface of the oil injection pump driveshaft then install Oil Seal Protector Tool at the end of the shaft Twist the shaft while pushing it through the oil and water pump seals until the...

Страница 116: ...sition 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 12 Secure the hoses to the water pump cover Pressure...

Страница 117: ...tank NOTE If coolant is required mix coolant for a tem perature of 36 C 34 F Follow mixing recommen dations of the manufacturer of the coolant INSPECTING COOLANT HOSES AND CLAMPS All coolant hoses and...

Страница 118: ...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 crystallizati...

Страница 119: ...t engines will produce maximum horsepower in the low RPM ranges and pro vide good mid range fuel economy but they sacrifice top end performance The APV system does not increase engine horsepower but i...

Страница 120: ...on then shutting down Check for correct exhaust valve cable length specifica tions for model being worked on in this section Servomotor Makes No Attempt To Cycle If when running the engine the servomo...

Страница 121: ...e mark on the shaft of the servomotor Tighten the nut to 35 in lb MS401A FZ087A REMOVING DISASSEMBLING NOTE To avoid a parts mix up only remove one valve assembly at a time from the engine 1 Remove th...

Страница 122: ...e valve plate gasket properly positioned slide the exhaust valve through the valve plate and insert it into the valve stopper Secure with the retaining screw Tighten to 48 in lb FC112 NOTE Note that t...

Страница 123: ...nated RPM of 4500 at which the system is synchronized and checked by the ECM for proper operation occurring once each time the engine is started This system automatically adjusts the ignition timing t...

Страница 124: ...es The fuel is then routed through a high pressure fuel hose to the fuel rail The fuel pressure is maintained in the fuel rail by the fuel regulator With the fuel pressure maintained at a constant psi...

Страница 125: ...ve 75 C 167 F the temperature sensor starts to richen the fuel mixture At this time the check engine light will flash constantly Once the engine coolant temperature reaches the specified temperature 9...

Страница 126: ...s 2 Pull the fuel rail with the injectors from the cylinders and disconnect the wiring harness from each injector 3 Carefully remove the injector from the fuel rail Account for both gaskets Installing...

Страница 127: ...e and adjusts the fuel ignition timing and APV calibration Resistance will increase as the temperature rises FUEL PUMP CIRCUIT The fuel pump and its circuit are provided with current from the fuel pum...

Страница 128: ...12 Failure in ignition coils Code Trouble P0112 Intake air temp sensor 1 circuit low P0113 Intake air temp sensor 1 circuit high P0117 Coolant temp sensor 1 circuit low P0118 Coolant temp sensor 1 cir...

Страница 129: ...plug them to prevent leakage 3 Remove the fuel supply hose from the fuel rail 4 Loosen the flange clamps 5 Remove the oil pump control rod 6 Slide the throttle body assembly out of the flanges then lo...

Страница 130: ...oses to the throttle body using the clamps Throttle Cable REMOVING 1 Loosen the throttle cable from the bracket then remove the throttle cable from the pulley on the throttle body lever shaft 2 Remove...

Страница 131: ...ht by crimping the clamps until the two clamp areas touch XM282 4 Start the engine and inspect the fuel hoses and filter for any signs of leaks 5 Close the right side access panel Fuel Pump TESTING 1...

Страница 132: ...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 f...

Страница 133: ...line hose to the fuel pump making sure it locks into place 7 Install the upper and lower consoles using existing machine screws then install the seat see the Steer ing and Body section hood and access...

Страница 134: ...t union bolt install 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 t...

Страница 135: ...he specifications listed 9 If the oil injection pump output does not meet the specifications see TESTING CHECK VALVES in this sub section 10 Disconnect the oil usage tool remove the plug from the rese...

Страница 136: ...ty of the crankcase to the top ter minal B Install the hose from the fuel rail to the lower terminal C Secure using the existing clamps SNO 355A 3 Secure the right side skid plate using the existing s...

Страница 137: ...s 2 Install the rear spar tubes and secure to the chassis and steering support using the four cap screws Tighten to 23 ft lb XM210A XM212A 3 Connect the reverse alarm then use the two machine screws t...

Страница 138: ...n this position crank the engine over and check for spark If spark is now present adjust the throttle cable tension TESTING Throttle Control Switch 1 Disconnect the handlebar harness connector then co...

Страница 139: ...ev eral times to confirm results NOTE If at any point throughout the throttle range the meter reads no voltage open hold the throttle lever in that position If the voltage does not return the throttle...

Страница 140: ...should now be completely closed 2 Disconnect TPS wiring harness from the TPS then noting the position of the TPS remove the two screws securing the TPS to the throttle body and remove the sensor Insta...

Страница 141: ...high tension wires 2 Connect the red meter lead to one high tension wire then connect the black meter lead to ground 3 Resistance must be 5040 7560 ohms Spark Plug Cap 1 Remove the spark plug caps fr...

Страница 142: ...ght side skid plate and secure out of the way 2 For the DC voltage test connect the red meter lead to the red blue wire in the accessory connector then connect the black meter lead to the black wire i...

Страница 143: ...should go out after a few seconds If the icon stays illuminated while the engine is running the CCU ECM is receiving input that is outside of its established parame ters Accessing CCU Codes 1 Connect...

Страница 144: ...housing assembly to the handlebar 2 Set the selector to the OHMS position 3 Connect one tester lead to one pin then connect the other tester lead to the other pin PC253A 4 With the switch in the OFF p...

Страница 145: ...procedure 1 With the ignition switch plugged in place the emer gency stop switch to the OFF position 2 Connect the red tester lead to the black yellow wire then connect the black tester lead to a sui...

Страница 146: ...3 REMOVING 6000 1 Remove the seat and disconnect the battery then remove the hood and both access panels 2 Remove all springs securing the expansion chamber and resonator then remove the expansion cha...

Страница 147: ...er cable to the positive post of the battery 4 Holding the starter firmly down on a work bench touch the red jumper cable to the positive cable stud of the starter NOTE The starter motor must instantl...

Страница 148: ...ion chamber and secure using existing springs 10 Install the hood left and right side access panels 11 Connect both battery cables to the battery making sure both are secure then install the seat INST...

Страница 149: ...g spring retainer and pinion gear Retain all components DISASSEMBLING PINION 8000 NOTE This procedure does not require the starter motor to be removed from the snowmobile 1 Remove the drive clutch 2 I...

Страница 150: ...the pinion shaft slide the pinion gear spring retainer pinion spring and pinion stop note end for end orientation onto the shaft in their origi nal positions 2 Loosely secure the components from step...

Страница 151: ...ully seated 2 Position the O ring into the reservoir then secure the reservoir to the piston assembly using the existing screws Tighten securely 3 Connect the switch harness to the main wiring har nes...

Страница 152: ...1 5 and 6 9 ohms 4 In the element connector connect the ohmmeter between the green blue lead and the green lead 5 The meter must read between 5 5 and 23 0 ohms NOTE If either test is not within speci...

Страница 153: ...ther ohmmeter lead to the other pin PC253B 3 With the reverse button pressed in the meter must read less than 1 ohm of resistance With the reverse button released the meter must read OL infinite resis...

Страница 154: ...ion and there will be a small area in the rotation where the ohm reading will disappear then it will return again 5 Continue the clutch rotation and the ohms should appear at a very low value but will...

Страница 155: ...154 Troubleshooting Servomotor SERVO1A16...

Страница 156: ...155 SERVO2rv16...

Страница 157: ...5490 34 C 29 F 4 574 302000 36 C 97 F 0 937 6005 36 C 32 F 4 625 343000 34 C 93 F 1 004 6520 38 C 36 F 4 677 384000 32 C 90 F 1 072 7035 40 C 40 F 4 729 425000 30 C 86 F 1 139 7550 Temperature Volts...

Страница 158: ...70 76 C 169 F 0 339 349 6 C 21 F 3 113 7830 74 C 165 F 0 361 371 8 C 18 F 3 219 8490 72 C 162 F 0 383 393 10 C 14 F 3 325 9150 70 C 158 F 0 405 415 12 C 10 F 3 421 9422 68 C 154 F 0 438 445 14 C 7 F 3...

Страница 159: ...he adjuster 0743 395 3 Reverse the adjuster and install the cap screw with out washers into the adjuster Install the sheave adjuster and cap screw onto the driven clutch then tighten the cap screw unt...

Страница 160: ...ve Clutch Spanner Wrench tighten the puller If the drive clutch will not release sharply strike the head of the puller Repeat this step until the clutch releases 3 Remove the drive clutch and drive be...

Страница 161: ...h and driven clutch 4 Install the drive belt Check drive belt deflection Close the left side access panel 5 Either test drive the snowmobile or run the engine for five minutes then verify the drive cl...

Страница 162: ...er screw and install in through the clutch thrust washers and the cam arm Secure using new lock nut Tighten to 50 in lb 3 Place the spring and cover into position making sure the timing mark X on the...

Страница 163: ...e the movable sheave 5 Remove the stationary sheave then remove the plas tic spring seat Account for the driven spacer XM141 6 Remove the spring and remaining spring seat PC112 CLEANING AND INSPECTING...

Страница 164: ...at side toward the spring onto the torque bracket and place the spring into position PC112 NOTE Premature wear will result if the spring seat is not installed 2 Place the stationary sheave spring seat...

Страница 165: ...e cam to the movable sheave then grasp the cam and by working the movable sheave back and forth lift it up and off the shaft CM086 CM087 NOTE If changing cam angles move the cam 90 to its optional pos...

Страница 166: ...e limit the bushing must be replaced Assembling 1 Install the spacer and the movable sheave onto the driven clutch shaft 2 Place the retaining ring and spring into the driven clutch then place the rol...

Страница 167: ...el then remove the cap screw and washer securing the stationary sheave to the driven shaft SNO 544 2 Slide the stationary sheave off the driven shaft and account for the drive belt and offset shims SN...

Страница 168: ...ide of the bore is installed toward the inside or the retaining ring will not seat into the groove of the spider shaft ASSEMBLING 1 Place the movable sheave onto the Driven Clutch Compressor Tool then...

Страница 169: ...point C If the bar either will not clear the inside edge or is more than the specified amount the offset must be corrected 0747 959 CORRECTING OFFSET ZR 4000 LXR 1 To correct offset the driven clutch...

Страница 170: ...ntered between the drive clutch and driven clutch push down on the drive belt just enough to remove all slack Note the amount of deflection on the ruler at the bottom of the straight edge The deflecti...

Страница 171: ...od then loosen the quarter turns securing the lower console to the skid panels and secure out of the way 2 Remove the drive and driven clutches 3 Remove the screws securing the PTO engine mount plate...

Страница 172: ...f brake fluid Do not com press the brake lever 18 Remove the retaining ring securing the brake disc to the driveshaft and remove the brake disc NOTE It may be necessary to use Brake Caliper Bearing Pu...

Страница 173: ...e Suspension section 7 Install the brake shield and left side footrest Tighten the cover cap screws to 8 ft lb 8 Install the driven shaft w mount plate from the left side then secure the PTO side engi...

Страница 174: ...the way 2 Remove the drive and driven clutches 3 Remove the screws securing the PTO engine mount plate to the engine and the chassis 4 Remove the resonator then remove the right side footrest 5 Remove...

Страница 175: ...ews with lock nuts Tighten the screws to 14 ft lb 2 Place the driveshaft drive sprocket assembly into the tunnel brake end first then into the chain case drive shaft bearing 3 Install the inner brake...

Страница 176: ...r then install the reverse actuator and with a drop of blue Loctite 243 on each screw secure the actuator to the chain case cover 15 Connect the speed sensor connector A the gear indicator switch conn...

Страница 177: ...s for wear or damage INSTALLING NOTE The drive sprockets must be installed from the brake side YM 075B NOTE Prior to installing the sprockets onto the driveshaft lightly chamfer the inside edge of the...

Страница 178: ...re the deflection distance between the bottom of the wear strip and the inside surface of the track clip Com pare the measurement with the chart in the General Information section NOTE Measurement is...

Страница 179: ...drive lugs closer to the rear idler wheel loosen the idler wheel axle cap screw then rotate the adjusting bolt clockwise 1 to 1 1 2 turns 0745 811 6 Check the track alignment and make the necessary a...

Страница 180: ...ctic Cat recommends the removal and disassembly of the brake caliper assembly when changing the brake fluid 1 Slide a piece of flexible tubing over the ball of the bleeder valve and direct the other e...

Страница 181: ...and the brake lever feels firm when compressed fill the reservoir then install and secure the cover Remove the tube from the bleeder valve CHECKING AND REPLACING BRAKE PADS 1 Remove the brake shield t...

Страница 182: ...per hous ing completely loosen track tension 7 Remove the retaining ring from the driveshaft and remove the brake disc then remove the cap screws securing the inner caliper driveshaft bearing housing...

Страница 183: ...n 0 20 in If the brake pad thickness is less than specified replacement of both pads is neces sary 6 Inspect the brake hose for cracks and deterioration and check the condition of the threaded connect...

Страница 184: ...d and footrest then install the drive belt see Drive Belt in this section and driven clutch Tighten the driven clutch cap screw to 20 ft lb 11 Adjust the track tension see Track Tension in this sectio...

Страница 185: ...is a non serviceable component If any wear or damage is detected the master cylinder must be replaced 3 Inspect the brake fluid hose for cracks deterioration and the condition of the fittings threade...

Страница 186: ...olt Problem Brakes Drag Condition Remedy 1 Master cylinder damaged faulty 2 Brake pads worn tapered 1 Replace master cylinder 2 Replace pads Problem Snowmobile Won t Stop Have to Pull Too Hard on Leve...

Страница 187: ...xcessive 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 compo...

Страница 188: ...kis position A However for controlled cornering more pressure is needed on the skis So when the driver decelerates com ing into a corner the center of gravity is transferred for ward putting the requi...

Страница 189: ...edure NOTE The shock should not be under load when adjusting Raise the rear end of the snowmobile NOTE Adding air pressure will increase the air spring force reducing air pressure will decrease air sp...

Страница 190: ...threads are exposed between the adjuster nut and the threaded shock body as an initial set ting Rear spring pre load adjustment is accomplished by loos ening the adjuster nut locking collar B from th...

Страница 191: ...ock of wood under the rear of the sus pension just in front of the rear idler wheels to assist in collapsing the suspension 4 Collapse the rear suspension until the rear arm is firmly against the coup...

Страница 192: ...rctic Cat recommends that when disassembling and assembling the suspension all stock mounting locations be used as shown in the following illustrations 0749 567 0747 988 CAUTION All stock mounting loc...

Страница 193: ...192 0747 414 M 141 High Country Models...

Страница 194: ...On the ZR 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 t...

Страница 195: ...ks REMOVING 1 Remove the cap screw and lock nut securing the idler wheel to the idler wheel mounting block then remove the cap screw and lock nut securing the mounting block to the slide rail SNO 593...

Страница 196: ...e shock absorber eyelet welds at each end for any cracks signs of separation or for unthread ing INSTALLING 1 Place the front arm shock axle assembly into position on the skid frame making sure the sp...

Страница 197: ...arm spacers for wear or damage INSTALLING 1 Install the existing washers onto both axles then install the axles into the front arm and secure using existing cap screws threads coated with blue Loctite...

Страница 198: ...the pivot and account for the cap screws lock nuts and sleeves FZ102A 9 Remove the cap screw securing the rear arm to the idler arm Account for the aluminum axle FZ101A 10 Remove the cap screw and lo...

Страница 199: ...rber cap screw as the shock eyelet must be free to pivot NOTE Install the rear arm springs onto the adjuster blocks after the skid frame has been installed 5 Slide the sleeve and spring onto the idler...

Страница 200: ...ing the Rear Suspen sion Spring Tool remove the springs from the adjust ing cams 2 Mark the offset arm and the idler arm for assembly purposes FZ034 3 Loosen the cap screws and lock nuts securing the...

Страница 201: ...M089 5 Install both spring sleeves onto the rear arm then install the suspension springs into the spring slides then onto the idler arm 6 Install spacers onto the idler arm 7 Align the marks on the id...

Страница 202: ...ew 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 cra...

Страница 203: ...nner 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 wheel was installed in from step 5 then wit...

Страница 204: ...and XF secure the front of the skid frame to the tunnel using the existing cap screws flat wash ers and lock nuts NOTE To aid in centering the front arm with the hole in the tunnel position the skid...

Страница 205: ...g the rear suspension NOTE Special tools are available from the Arctic Cat Service Parts Department NOTE If service work is needed on any FOX shocks the shock will have to be removed and sent to FOX o...

Страница 206: ...in order 5 Remove the bearing end cap 6 Items to inspect A Shock rod for straightness nicks or burrs B Bearing end cap clean inspect or replace C Inside of shock body for scratches burrs or exces sive...

Страница 207: ...ew synthetic shock oil to bot tom of threads ZR 007 6 With the bearing cap positioned at the top of the shock rod install the piston valve stack into the shock body then gently tap the top of the rod...

Страница 208: ...shock with nitrogen to 200 psi and until the shock eyelet fully extends ZR 018 9 Install the screw into the shock body ZR 004 10 Compress the shock eyelet until it bottoms out then the shock eyelet s...

Страница 209: ...208 NOTES...

Страница 210: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 847...

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