Arctic Cat ZR 6000 R CROSS COUNTRY User manual

OPERATOR’S MANUAL
www.arcticcat.com
ZR 6000 R CROSS COUNTRY

Limited Warranty
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on each new Arctic Cat Snowmobile it assembles and on each
genuine Arctic Cat Snowmobile part and accessory assembled and sold by an authorized Arctic Cat Snowmobile dealer. The limited warranty on an Arctic Cat
Snowmobile is extended to the original retail purchaser for the time periods described below; however, the balance of the remaining warranty may be transferred to
another party unless the purchase is for commercial use (see below). Warranty coverage is only available in the country in which the original retail purchase occurs
to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the remaining warranty.
Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products will function properly when used with an ArcticCat
Snowmobile or will not damage the Arctic Cat Snowmobile. Arctic Cat does not assume any liability for incidental or consequential damages.
Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any parts that are found to be warrantable in material or workmanship.
This repair work MUST be done by an authorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costs will be paid by Arctic
Cat. The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such
parts at its factory for final determination if warranty should apply.
The warranty periods are as follows:
1. For snowmobiles used for recreational purposes:
—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR from December 1 of the current year.
—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.
2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from the date of invoice and/or 5000 MILES whichever comes first
(non-transferable).
3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.
Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal 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 Plugs Drive Clutch/Driven Clutch Wear Parts
Wear Strips Shock Absorber(s) - Standard* Shock Absorber(s) - Rebuildable**
* Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock, corroded or pitted shaft, peeling chrome.
** Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted) - replace for defective shock, corroded or pitted shaft, peeling
chrome.
The following will VOID Arctic Cat’s warranty:
1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (if stored for extended periods), and/or serviceas
recommended in the Operator’s Manual.
2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer.
3. Use of an improper fuel mixture ratio.
4. Use of improper carburetor jets.
5. Use of improper gasoline, lubricating oils, or spark plugs.
6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.
7. Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.
8. Use of the snowmobile in any way for racing purposes.
9. Removal of the engine for use in another vehicle.
10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.
11. Use of parts not sold or approved by Arctic Cat.
12. Track and tunnel damage resulting from either ice stud or hooker plate installation.
13. Damage due to improper transportation.
Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic, punitive, consequential and incidental damages, lost profits, and loss
of use. Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. Arctic
Cat’s aggregate liability may not exceed the price of the product. The law of the State of Minnesota shall apply to all claims or disputes, exclusive of its conflicts of
law provisions.
IMPLIED WARRANTY EXCLUSION AND DISCLAIMER
To the fullest extent permitted by law, Arctic Cat excludes and disclaims all implied warranties of merchantability and fitness for a particular purpose.
If you are not satisfied with warranty service or repairs, you should contact Arctic Cat at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.

FOREWORD
Congratulations! You have chosen a quality Arctic Cat Snowmobile designed and manufactured to give depend-
able service. Be sure, as the owner/operator of an Arctic Cat Snowmobile, to become thoroughly familiar with its
basic operation, maintenance, and off-season storage procedures. Read this manual and the accompanying Snow-
mobile Safety Handbook before operating the snowmobile to ensure safe and proper use of your new Arctic Cat
Snowmobile. Always operate the snowmobile within your level of skill and current terrain conditions.
The Operator’s Manual, Snowmobile Safety Handbook, and snowmobile decals display the words Warning, Cau-
tion, and Note to emphasize important information. The symbol !WARNING identifies personal safety-
related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or
even death. A CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow
the directive because it deals with the possibility of damaging part or parts of the snowmobile. The symbol
NOTE: identifies supplementary information worthy of particular attention.
This manual covers operator-related maintenance, operating instructions, and off-season 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 illustrations were technically correct. Some illustrations used in this
manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc.
constantly refines and improves its products, no retroactive obligation is incurred.
This Operator’s Manual should be considered a permanent part of the snowmobile and must remain with the snow-
mobile at the time of resale. If the snowmobile changes ownership more than once, contact Arctic Cat Inc., Service
Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.
Every Arctic Cat Snowmobile meets or exceeds the standards of the Snowmobile Safety and Certification Commit-
tee and displays the SSCC decal. Arctic Cat endorses and encourages the safe use of all snowmobiles. Always wear
a helmet and eye protection. Drive with caution, observe all state and local regulations, and respect the rights of
others. ISMA members like Arctic Cat do their part to improve trails, sponsor events, and generally support the
sport of snowmobiling. As a member of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmo-
biling through education, charity, and research programs.
© 2014 Arctic Cat Inc.
Printed in U.S.A. September 2014

If the snowmobile is purchased
through the Team Arctic Race
Department Racing Program, there
is no warranty.
Reference Information
The Arctic Cat Snowmobile has two important identi-
fication numbers. The Vehicle Identification Number
(VIN) is stamped on the side of the tunnel. The Engine
Serial Number (ESN) is stamped into the crankcase of
the engine.
These numbers are required by the dealer to complete
warranty claims properly. No warranty will be allowed
by Arctic Cat Inc. if the engine serial number or VIN is
removed or mutilated in any way.
Always provide the snowmobile name, VIN, and ESN
when contacting an authorized Arctic Cat Snowmobile
dealer for parts, service, accessories, or warranty. If
the complete engine must be replaced, ask the dealer to
notify Arctic Cat for correct registration information.
Write the appropriate information for your Arctic Cat
Snowmobile in the spaces below. Always use these
numbers when referring to your snowmobile.
Model: ____________________________________
Date of Purchase: ____________________________
VIN (Vehicle Identification Number):_____________
ESN (Engine Serial Number):___________________
Your Arctic Cat Dealer: ________________________
Address: ____________________________________
Phone: _____________________________________
! WARNING
This snowmobile is a very high performance snowmo-
bile. Because it does accelerate rapidly and is capable
of very high speeds, it should not be operated by a
novice or an inexperienced operator. Never accelerate
rapidly or drive at high speed beyond the limits of visi-
bility or without being totally familiar with the terrain
and what lies in front of you. Obey speed limits and
never operate at speeds that do not allow adequate
maneuvering and stopping distances. Read and study
the entire Operator’s Manual and Safety Handbook.
Failure to follow this warning could result in personal
injury to yourself or others.
PARTS AND ACCESSORIES
When in need of replacement parts, oil, or accesso-
ries for your Arctic Cat Snowmobile, be sure to only
use GENUINE ARCTIC CAT PARTS, OIL, AND
ACCESSORIES. Only genuine Arctic Cat parts, oil,
and accessories are engineered to meet the standards
and requirements of your Arctic Cat Snowmobile.
For a complete list of accessories, refer to the current
Arctic Cat Accessory Catalog.
To aid in service and maintenance procedures on this
snowmobile, an Illustrated Parts Manual is available
through your local Arctic Cat Snowmobile dealer.

1
TABLE OF CONTENTS
Specifications/Charts/Patterns/Diagrams.............. 2-15
General Specifications............................................ 2
Engine Specifications ............................................. 2
Torque Specifications.............................................. 2
Torque Conversions (ft-lb/N-m)............................... 3
Tightening Torque (General Bolts) .......................... 3
Crankshaft Runout/Repair Specifications ............... 3
Crankshaft Runout/Repair Specifications ............... 3
Arctic Power Valve (APV) System Specifications.... 3
Component Voltage/Resistance Chart - Water
Temperature......................................................... 4
Drive System Specifications ................................... 5
Drive Clutch/Driven Clutch Optional Components.. 5
Drive Clutch Cam Arms (w/Set Screw)................... 5
Chain Case Performance Calibrations.................... 6
Chains and Sprockets............................................. 7
Rear Spring Selection Chart................................... 7
Installed Spring Rate Chart .................................... 7
Front Suspension Sway Bar.................................... 7
Rebuildable Shock Tools Required ......................... 8
Optional Front Arm Shock Springs ......................... 8
Valve Stacks/Specifications .................................... 9
Rebuildable Shock Accessory Part Numbers ....... 10
Fraction/Decimal Conversion Chart ...................... 11
Drill Bit Sizes (Number) Chart............................... 11
MM/IN. Conversion Chart ..................................... 12
Wiring Diagram - Hood Harness........................... 13
Wiring Diagram - Ignition/Main Harness (p/n 1686-
732) ................................................................... 15
Setup Instructions ............................................... 17-22
Removing Snowmobile From Crate/Handlebar
Assembly ........................................................... 17
Installing Windshield ............................................ 17
Installing Spindle/A-Arm ....................................... 17
Installing Front Shock Absorbers .......................... 17
Installing 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 ............................................ 23-25
Control Locations.................................................. 23
Arctic Power Valve (APV) System ......................... 23
Exhaust Controlled Timing (ECT) System ............ 23
Arctic Power Valve (APV) System ......................... 23
Testing Exhaust Temperature Sensor ................... 24
Handlebar Tilt........................................................ 24
Rear Bumper......................................................... 24
Exhaust System .................................................... 24
Liquid Cooling System .......................................... 24
Drive Clutch And Driven Clutch............................. 25
Drive Clutch/Driven Clutch Alignment................... 25
Shock Absorbers................................................... 25
Track Studs ........................................................... 25
Towing ................................................................... 25
Operating Instructions ......................................... 26-27
Starting And Stopping Engine............................... 26
Braking.................................................................. 26
Emergency Stopping............................................. 27
Lubrication................................................................ 28
Chain Case ........................................................... 28
Rear Suspension .................................................. 28
Maintenance........................................................ 29-87
Periodic Maintenance Checklist ............................ 29
Pre-Race/Practice Checklist ................................. 30
Engine................................................................... 30
Track Drive ............................................................ 49
Drive Sprockets..................................................... 50
Brake System........................................................ 51
Brake Fluid ............................................................ 51
Checking Brake Lever Travel ................................. 52
Bleeding Brake System......................................... 52
Checking/Changing Brake Pads ........................... 53
Drive Belt............................................................... 54
Drive Clutch........................................................... 55
Driven Clutch......................................................... 56
Servicing Float X Evol Shock Absorbers............... 61
Rear Suspension .................................................. 77
Servicing Zero-X Shock Absorbers....................... 78
Adjusting Rear Transfer Adjuster Cams ................ 85
Lights .................................................................... 85
Ski Wear Bar ......................................................... 86
Rail Wear Strip ...................................................... 87
Performance Tips ..................................................... 88
Preparation For Storage........................................... 89
Preparation After Storage......................................... 90
Genuine Arctic Cat Products.................................... 91
Special Tools ..................................................... 92-101
Declaration of Conformity................ Inside Back Cover

2
General Specifications
Engine Specifications
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
* w/Green Loctite #609
** w/Blue Loctite #243
*** w/Oil
Chassis Length 307 cm (121 in.)
Height 122 cm (48 in.)
Width 125-128 cm (49.25-50.25 in.)
Spindle Center-to-Center Distance 106-109 cm (41.90-42.90 in.)
Dry Weight (approx) 225 kg (495 lb)
Gas Tank Capacity 44.3 l (11.7 U.S. gal.)
Chain Case Lubricant Capacity 355 ml (15 fl oz)
Gasoline (Recommended) 91 Octane (minimum)
Engine Oil Arctic Cat CTec2
Chain Case Lubricant Arctic Cat Chain Lube
Suspension Grease All-Temperature
Brake Fluid High-Temp DOT 4
Taillight/Brakelight Bulb p/n 3303-849
Headlight Bulb p/n 0109-724
Cooling System Capacity 3.81 l (4.0 U.S. qt)
Starting System Manual Recoil
Engine Number 0962-011
Displacement 599 cc
Bore x Stroke 73.8 x 70 mm
Compression Ratio 6.62:1
Cooling System Liquid
Ignition Timing (Engine Warm) 16.5° @ 2000 RPM 0.072”
Spark Plug (NGK) BPR9ES
Spark Plug Gap 0.028-0.031”
Piston Skirt/Cylinder Clearance 0.0041-0.0053”
Piston Ring End Gap 0.012-0.0196”
Cylinder Trueness Limit 0.004”
Piston Pin Diameter 0.8659-0.8661”
Piston Pin Bore Diameter 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 0.512”
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
DRIVE SYSTEM
Item Secured to Torque
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 Bracket 27
Chain Case (Cap Screw) Chassis 96 in.-lb
Chain Case (Torx-Head Screw) Chassis 12
Chain Case Cover Chain Case 12
Brake Caliper Chassis 25
Outside Caliper Housing Inside Caliper Housing 25
Brakeline Caliper 25
Brakeline Master Cylinder 25
Brake Caliper Shield Cover 96 in.-lb
STEERING/FRONT SUSPENSION/CHASSIS
Item Secured to Torque
ft-lb
Ski Spindle 35
Ski Wearbar 8
Ski Ski Handle 54 in.-lb
Handlebar Adjuster Post 15
Steering Support Mounting Block 8
Steering Tie Rod Link Steering Post 35
Steering Tie Rod Link Steering Arm 20
Steering Post Cap Riser Block 15
Steering Post Chassis 55
Steering Tie Rod 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) Chassis 23
A-Arm (Lower) Chassis (Front) 65
A-Arm (Lower) Chassis (Rear) 45
A-Arm Spindle 45
Shock Absorber Spindle 45
Shock Absorber Chassis 45
Sway Bar Link A-Arm/Sway Bar Link 23
Sway Bar Mounting Bracket Chassis 9
REAR SUSPENSION
Wear Strip Rail 50 in.-lb
End Cap Rail 80 in.-lb
Mounting Block Rail 20
Rear Arm Rail 45
Rear Arm Idler Arm 55
Spring Slide Rail 20
Front Arm Rail 52
Coupler Block Axle Rail 40
Limiter Strap Rail Support 72 in.-lb
Rear Tri Hub Wheel Rear Tri Hub Wheel 50 in.-lb
Rear Wheel Axle Rail 34
Skid Frame Tunnel 55**
Front Shock Rail 50
Rail Support Rail 20
Limiter Strap Front Arm 72 in.-lb
DRIVE SYSTEM
Item Secured to Torque
ft-lb

3
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
Crankshaft Runout/
Repair Specifications
To use the specifications, first refer to the drawing; then
find the letter indicating the specification and refer to the
chart below the illustration.
NOTE: The proper location for checking crankshaft
runout is the very edge of the straight portion of the
shaft where the oil seal makes contact. From the illus-
tration, note that three check points are called out: at
either end, out on the taper as shown, and also on the
center bearing race. The crankshaft must be supported
on the inner bearings using V blocks.
0747-810
Arctic Power Valve (APV)
System Specifications
0735-516
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 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 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
Type of Bolt
Thread
Diameter A
(mm)
Tightening
Torque
(Grade 8.8) 5 60 in.-lb
6 96 in.-lb
8 20 ft-lb
10 40 ft-lb
12 65 ft-lb
(Grade 10.9) 6 12 ft-lb
8 28 ft-lb
10 50 ft-lb
12 95 ft-lb
VALVE POSITION CYCLE RPM
Mid-Open
Full-Open
67-7500 (Low/High Alt)
77-8500 (Low/High Alt)
APV CABLE LENGTH
6000 36.5 mm ± 1 mm

4
Electrical Specifications
* Harness plugged in
The main harness connectors must be unplugged
(except on the primary coil and regulator/rectifier
tests), the spark plugs removed and grounded, and by
pulling the recoil starter rope briskly.
NOTE: Lighting coil output is unregulated volt-
age.
Component Voltage/
Resistance Chart - Water
Temperature
Component Test Value + Test Connections -
Spark Plug Cap 4000-6000 ohms cap end cap end
Oil Level Sensor Less than 1 ohm
(float end down)
terminal terminal
Ignition Switch Less than 1 ohm
(key in OFF
position)
terminal terminal
(Normally Open Ignition)
Ignition Coil (Primary)
(Secondary)
0.24-0.36 ohm
5040-7560 ohms
black/white
high tension wire
white/blue
high tension wire
Charge Coil (1) 8.8-13.2 ohms black/red green/red
Charge Coil (2) 8.8-13.2 ohms brown/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 10-14 ohms terminal terminal
Injection Coil 15.2-22.8 ohms blue/white blue/white
Fuel Pump Coil 1.52-2.28 ohms orange orange
Servomotor 12 DC Volts red/black
(counterclock-
wise)
black/red
(clockwise)
black/red
(counterclock-
wise)
red/black
(clockwise)
Voltage Regulator/
Rectifier*
9-14.5 DC Volts red/blue black
! WARNING
Most voltages generated by the ignition system are suf-
ficient to interrupt pacemakers! All technicians, espe-
cially those using pacemakers, must avoid contact with
all electrical connections when pulling the recoil starter
rope or after the engine has been started.
Temperature 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 °F 1.623 2250
102 °C 216 °F 0.171 161 20 °C 68 °F 1.705 2400
100 °C 212 °F 0.185 169 18 °C 64 °F 1.806 2670
98 °C 208 °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
88 °C 190 °F 0.235 240 6 °C 43 °F 2.444 4590
86 °C 187 °F 0.250 256 4 °C 39 °F 2.561 5010
84 °C 183 °F 0.265 273 2 °C 36 °F 2.678 5430
82 °C 180 °F 0.280 289 0 °C 32 °F 2.795 5850
80 °C 176 °F 0.295 305 -2 °C 28 °F 2.901 6510
78 °C 172 °F 0.317 327 -4 °C 25 °F 3.007 7170
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 3.517 9694
66 °C 151 °F 0.471 475 -16 °C 3 °F 3.613 9966
64 °C 147 °F 0.504 505 -18 °C -0.4 °F 3.709 10238
62 °C 144 °F 0.537 535 -20 °C -4 °F 3.805 10510
60 °C 140 °F 0.570 565 -22 °C -8 °F 3.885 13688
58 °C 136 °F 0.598 609 -24 °C -11 °F 3.965 16866
56 °C 133 °F 0.626 653 -26 °C -15 °F 4.045 20044
54 °C 129 °F 0.654 697 -28 °C -18 °F 4.125 23222
52 °C 126 °F 0.682 741 -30 °C -22 °F 4.205 26400
50 °C 122 °F 0.710 785 -32 °C -26 °F 4.267 30520
48 °C 118 °F 0.759 849 -34 °C -29 °F 4.329 34640
46 °C 115 °F 0.808 913 -36 °C -32 °F 4.391 38760
44 °C 111 °F 0.857 977 -38 °C -36 °F 4.453 42880
42 °C 108 °F 0.906 1041 -40 °C -40 °F 4.515 47000
40 °C 104 °F 0.955 1105 -42 °C -44 °F 4.553 55100
38 °C 100 °F 1.023 1214 -44 °C -47 °F 4.591 63200
36 °C 97 °F 1.091 1323 -46 °C -51 °F 4.629 71300
34 °C 93 °F 1.159 1432 -48 °C -54 °F 4.667 79400
32 °C 90 °F 1.227 1541 -50 °C -58 °F 4.705 87500
30 °C 86 °F 1.295 1650

5
Drive System
Specifications
Drive Clutch/Driven
Clutch-Related
Specifications
Drive Clutch/Driven
Clutch Optional
Components
*Lightweight driven clutch only.
Drive Clutch Cam Arms
(w/Set Screw)
* Notched Cam Arm
Model Altitude
Drive
Clutch
Spring
Cam
Arm
Driven
Clutch
Spring
Torque
Bracket
Drive
Belt
Engagement
RPM
Peak
RPM
Top
Gear
Bottom
Gear
Chain
Pitch
ZR 6000R Cross Country 0-5000 Green 64g Black/Blue 44°/42° 0627-083 42-4600 81-8200 23T 40T 86
ALIGNMENT BAR
OFFSET P/N CENTER-TO-CENTER OFFSET FLOAT
0644-428 12.10” 1.485” None
ARCTIC CAT DRIVE CLUTCH SPRING CHART
p/n Rate @ 2 9/16" Rate @ 1 5/16" Color
LIGHT 0646-439 50 lb 250 lb Black/White
0646-148 53 lb 224 lb Blue
0646-150 72 lb 188 lb Silver
0646-149 74 lb 228 lb Red
0646-432 74 lb 228 lb Black/Red
0646-433 75 lb 275 lb Black/Gold
0646-376 75 lb 275 lb Gold
0646-252 103 lb 315 lb Green
0646-147 114 lb 267 lb Yellow/Green
0646-373* 114 lb 257 lb Yellow/Green
0646-155 121 lb 240 lb Purple
0646-229 122 lb 285 lb Yellow/White
0646-379* 122 lb 285 lb Yellow/White
0646-035 143 lb 286 lb Orange/
Black
0646-447
(Titanium)
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/
58-48-36
0648-749 Black/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/
48-42-36
0648-792 Black/Orange 180/280
ARCTIC CAT DRIVE CLUTCH CAM ARMS
p/n Grams p/n Grams
0746-661 52.0 0746-712 77.0
0746-662 52.0 0746-713 48.0
0746-663 52.0 0746-715 77.0
0746-664 52.0 0746-716 73.0
0746-666 55.0 0746-742 83.5
0746-668 55.0 0746-744 50.0
0746-669 60.0 0746-748 46.0
0746-670 65.0 0746-749 65.0
0746-671 70.0 0746-771 44.0
0746-672 75.0 0746-772 42.0
0746-673 80.0 0746-773 85.0
0746-676 70.0 0746-786 63.0
0746-678 55.0 0746-787 44.0
0746-687 57.0 0746-788 47.5
0746-689 69.0 0746-789 42.0
0746-690 47.0 0746-791 60.0
0746-691 44.0 0746-792 47.0
0746-692 50.0 0746-793 63.0
0746-694 63.0 0746-814 83.0
0746-695 67.0 0746-821 82.0
0746-696 63.0 0746-822 71.5
0746-698 64.0 0746-824 66.0
0746-699 66.0 0746-825 50.0
0746-701 49.0 0746-826 64.0*
0746-702 57.5 0746-830 60.0
0746-703 68.0
0746-704 51.0
0746-708 51.0
0746-710 72.0

6
Chain Case Performance
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 acceptable chain tension.

7
Chains and Sprockets
Rear Spring Selection
Chart
Below is a list of rear suspension springs and specifi-
cations. A longer spring in areas (D) and (E) can be
selected if cut off to match the original spring. The
replacement spring must match the original spring in
areas (C), (D), and (E).
0730-218
* Production (Sno Cross) **Production (Cross Country)
NOTE: The wire diameter and length of the spring
have a large influence over the valving of the
shocks.
Installed Spring Rate
Chart
Front Suspension
Sway Bar
NOTE: Sway Bar Mounting Kit (p/n 6639-001).
Part
Number Sprocket
2602-582 SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE)
2602-523 SPROCKET, REX-20T FWD-(13 WIDE/19 SPLINE)
2602-377 SPROCKET, REX-21T FWD-(13 WIDE/19 SPLINE)
2602-335 SPROCKET, REX-22T FWD-(13 WIDE/19 SPLINE)
2602-403 SPROCKET, REX-23T FWD-(13 WIDE/19 SPLINE)
2602-666 SPROCKET, REX-19T FWD-(13 WIDE/19 SPLINE)
2602-212 SPROCKET, REX-21T FWD-(13 WIDE/19 SPLINE)
2602-461 SPROCKET, REX-22T FWD-(13 WIDE/19 SPLINE)
2602-405 SPROCKET, 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-41T FWD-(13 WIDE/19 SPLINE)
2602-364 SPROCKET, REX-48T FWD-(13 WIDE/19 SPLINE)
2602-363 SPROCKET, REX-49T FWD-(13 WIDE/19 SPLINE)
2602-548 SPROCKET, REX-50T FWD-(13 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 WIDE)
2602-365 CHAIN, REXNORD-84P (13 WIDE)
2602-373 CHAIN, REXNORD-90P (13 WIDE)
2602-710 CHAIN, REXNORD-86P (13 WIDE)
2602-733 CHAIN, REXNORD-92P (13 WIDE)
P/N
Wire
Diameter
(A)
Angle
(B)
Number
of
Coils
Coil
Width
(C)
Length
(D)
Length
(E)
Degree
(In lb)
1704-382/
383
(Light)
.359 90° 5.75 3.00 15.62 4.60 17
1704-384/
385
(Heavy)
.375 90° 5.75 3.00 15.62 4.60 20
1704-916/
917
.405 120° 5.90 3.20 15.62 4.70 24
2704-224/
225
.437 105° 6.80 3.75 15.62 4.70 27.3
1704-576/
577
.405 90° 6.75 3.65 18.50 5.50 18.5
2704-384/
385
.405 115° 6.80 3.65 15.62 4.70 18.9
2704-380/
381*
.437 92° 6.75 3.75 15.62 4.70 27.4
2704-382/
383**
.405 89° 6.75 3.65 15.62 4.70 18.9
P/N Suspension Fully
Extended
(in.-lb - Adjuster Set1&1)
Suspension Fully
Extended
(in.-lb - Adjuster Set3&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 Suspension Fully
Collapsed
(in.-lb - Adjuster Set1&1)
Suspension Fully
Collapsed
(in.-lb - Adjuster Set3&3)
1704-382/383 3740 4080
1704-384/385 4411 4812
1704-916/917 3840 4320
2704-224/225 5130 5670
1704-576/577 4070 4440
2704-380/381 5918 6466
2704-382/383 4196 4574
2704-384/385 3213 3591
Sway Bar p/n Bushing p/n Description
2703-615 2603-944/945 (inc.) 11.1 mm diameter
2703-793 2603-946/947 (inc.) 12.7 mm diameter

8
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 LB 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 70 6
2704-750 90 6
2704-751 110 6

9
Valve Stacks/
Specifications
CD Knob @ 12 clicks from full closed; RB Knob @ 12 clicks from full closed.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb).
Tighten the shaft nut to 3.0 kg-m (22 ft-lb). Shocks charged at 250 psi (nitrogen)/80/200 psi (air).
Green Loctite #620 on shock eyelet threads.
Compression @ 12 clicks counterclockwise from full stop.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb). Tighten shaft nut to 3.9 kg-m (28 ft-lb). Shock
charged at 250 psi. Green Loctite #620 on shock eyelet threads.
CD Knob @ 12 clicks from full closed; RB Knob @ 5 clicks counterclockwise.
Shock charged at 250 psi. Green Loctite #620 on shock eyelet threads.
Eyelets tightened to 3.9 kg-m (28 ft-lb). Piston nut tightened to 3.0 kg-m (22 ft-lb).
Tighten the shaft nut to 3.9 kg-m (28 ft-lb).
Part Number Description Compression (Piston Side) Rebound (Piston Side)
3703-346/347 Ski Shock 1.300 x 0.008 in. 1.100 x 0.008 in.
Extended Length: 18.94 in. Rebuild Kit - p/n 2603-929 1.300 x 0.008 in. 0.800 x 0.004 in.
Collapsed Length: 13.29 in. Rebuild Kit - p/n 3604-539 0.800 x 0.006 in. 1.125 x 0.080 in.
Ground
Stroke: 5.65 in. (Reservoir) 1.300 x 0.010 in.
1.250 x 0.010 in. 0.620 x 0.093 in.
Backup
1.100 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 0.006 in.
0.400 x 0.020 in. (BU)
0.400 x 0.020 in. (BU)
Part Number Description Compression
(Piston Side)
Rebound
(Piston Side)
2704-635 Front Arm Shock 1.300 x 0.008 in. 1.100 x 0.008 in.
Extended Length: 12.36 in. Rebuild Kit - p/n 3604-538 1.300 x 0.008 in. 0.600 x 0.004 in.
Collapsed Length: 8.56 in. Rebuild Kit - p/n 4604-017 0.800 x 0.004 in. (Center) 0.700 x 0.010 in.
Stroke: 3.80 in. (Reservoir) 1.300 x 0.10 (Ring) 1.125 x 0.080 in.
(Top Out)
1.100 x 0.004 in.
1.000 x 0.004 in. 0.620 x 0.093 in.
Backup
1.000 x 0.004 in.
0.700 x 0.004 in.
1.250 x 0.093 in. (Top Out)
Piston Orifice: None Piston Depth: 1.80 in.
Part Number Description Compression
(Piston Side)
Rebound
(Piston Side)
2704-636 Rear Arm Shock 1.600 x 0.004 in. (DB) 1.425 x 0.015 in.
Extended Length: 14.59 in. Rebuild Kit - p/n 2603-013 1.600 x 0.010 in. 1.425 x 0.015 in.
1.600 x 0.010 in. 1.425 x 0.012 in.
1.100 x 0.006 in. 1.350 x 0.012 in.
Collapsed Length: 10.06 in. Rebuild Kit - p/n 4604-017 1.600 x 0.012 in. 1.100 x 0.012 in.
Stroke: 4.53 in. (Reservoir) 1.600 x 0.012 in. 0.950 x 0.012 in.
1.600 x 0.012 in. 0.800 x 0.020 in.
1.425 x 0.010 in. 0.800 x 0.020 in.
1.350 x 0.010 in. 0.750 x 0.080 in.
1.100 x 0.008 in. 0.750 x 0.100 in. (Backup)
1.570 x 0.128 in. (Top Out)
Piston Orifice: None Piston Depth: 2.40 in.

10
Rebuildable Shock
Accessory Part Numbers
NOTE: When rebuilding Fox shocks, use only
Fox valves and/or pistons.
NOTE: Shock Oil (p/n 5639-530) is available from
Arctic Cat Service Department.
AC PN Description
2603-499 Valve: [0.500 OD X 0.252 ID X 0.006 TH]
2603-500 Valve: [0.600 OD X 0.252 ID X 0.010 TH]
2603-501 Valve: [0.700 OD X 0.252 ID X 0.010 TH]
2603-902 Valve: [0.550 OD X 0.377 ID X 0.020 TH]
3604-171 Valve: [0.600 OD X 0.377 ID X 0.004 TH]
3604-533 Valve: [0.600 OD X 0.377 ID X 0.012 TH]
2603-224 Valve: [0.620 OD X 0.377 ID X 0.015 TH]
0603-731 Valve: [0.700 OD X 0.377 ID X 0.004 TH]
0603-330 Valve: [0.700 OD X 0.377 ID X 0.006 TH]
0603-331 Valve: [0.700 OD X 0.377 ID X 0.008 TH]
0603-332 Valve: [0.700 OD X 0.377 ID X 0.010 TH]
0603-878 Valve: [0.700 OD X 0.377 ID X 0.012 TH]
0603-884 Valve: [0.700 OD X 0.377 ID X 0.015 TH]
0603-895 Valve: [0.800 OD X 0.377 ID X 0.004 TH]
0603-333 Valve: [0.800 OD X 0.377 ID X 0.006 TH]
0603-334 Valve: [0.800 OD X 0.377 ID X 0.008 TH]
0603-335 Valve: [0.800 OD X 0.377 ID X 0.010 TH]
0603-879 Valve: [0.800 OD X 0.377 ID X 0.012 TH]
0603-885 Valve: [0.800 OD X 0.377 ID X 0.015 TH]
0603-894 Valve: [0.900 OD X 0.377 ID X 0.004 TH]
0603-336 Valve: [0.900 OD X 0.377 ID X 0.006 TH]
0603-337 Valve: [0.900 OD X 0.377 ID X 0.008 TH]
0603-338 Valve: [0.900 OD X 0.377 ID X 0.010 TH]
0603-880 Valve: [0.900 OD X 0.377 ID X 0.012 TH]
0603-886 Valve: [0.900 OD X 0.377 ID X 0.015 TH]
0603-893 Valve: [1.000 OD X 0.377 ID X 0.004 TH]
0603-339 Valve: [1.000 OD X 0.377 ID X 0.006 TH]
0603-340 Valve: [1.000 OD X 0.377 ID X 0.008 TH]
0603-341 Valve: [1.000 OD X 0.377 ID X 0.010 TH]
0603-881 Valve: [1.000 OD X 0.377 ID X 0.012 TH]
0603-887 Valve: [1.000 OD X 0.377 ID X 0.015 TH]
0603-892 Valve: [1.100 OD X 0.377 ID X 0.004 TH]
0603-342 Valve: [1.100 OD X 0.377 ID X 0.006 TH]
0603-343 Valve: [1.100 OD X 0.377 ID X 0.008 TH]
0603-344 Valve: [1.100 OD X 0.377 ID X 0.010 TH]
0603-882 Valve: [1.100 OD X 0.377 ID X 0.012 TH]
0603-888 Valve: [1.100 OD X 0.377 ID X 0.015 TH]
0603-345 Valve: [1.250 OD X 0.377 ID X 0.006 TH]
0603-346 Valve: [1.250 OD X 0.377 ID X 0.008 TH]
0603-347 Valve: [1.250 OD X 0.377 ID X 0.010 TH]
0603-883 Valve: [1.250 OD X 0.377 ID X 0.012 TH]
0603-889 Valve: [1.250 OD X 0.377 ID X 0.015 TH]
0603-348 Valve: [1.300 OD X 0.377 ID X 0.006 TH]
0603-349 Valve: [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 Valve: [1.425 OD X 0.377 ID X 0.010 TH]
2604-632 Valve: [1.425 OD X 0.377 ID X 0.012 TH]
2604-633 Valve: [1.425 OD X 0.377 ID X 0.015 TH]
3604-577 Valve: [1.600 OD X 0.377 ID X 0.008 TH]
2604-631 Valve: [1.600 OD X 0.377 ID X 0.010 TH]
2604-683 Valve: [0.650 OD X 0.504 ID X 0.020 TH]
2604-469 Valve: [0.700 OD X 0.504 ID X 0.010 TH]
2604-470 Valve: [0.700 OD X 0.504 ID X 0.020 TH]
2604-471 Valve: [0.750 OD X 0.504 ID X 0.020 TH]
2604-472 Valve: [0.800 OD X 0.504 ID X 0.006 TH]
2604-473 Valve: [0.800 OD X 0.504 ID X 0.008 TH]
2604-474 Valve: [0.800 OD X 0.504 ID X 0.010 TH]
2604-475 Valve: [0.800 OD X 0.504 ID X 0.012 TH]
2604-476 Valve: [0.800 OD X 0.504 ID X 0.015 TH]
2604-477 Valve: [0.800 OD X 0.504 ID X 0.020 TH]
2604-478 Valve: [0.950 OD X 0.504 ID X 0.006 TH]
2604-479 Valve: [0.950 OD X 0.504 ID X 0.008 TH]
2604-480 Valve: [0.950 OD X 0.504 ID X 0.010 TH]
2604-481 Valve: [0.950 OD X 0.504 ID X 0.012 TH]
2604-482 Valve: [0.950 OD X 0.504 ID X 0.015 TH]
2604-483 Valve: [1.000 OD X 0.504 ID X 0.020 TH]
3604-149 Valve: [1.100 OD X 0.504 ID X 0.004 TH]
2604-484 Valve: [1.100 OD X 0.504 ID X 0.006 TH]
2604-485 Valve: [1.100 OD X 0.504 ID X 0.008 TH]
2604-486 Valve: [1.100 OD X 0.504 ID X 0.010 TH]
2604-487 Valve: [1.100 OD X 0.504 ID X 0.012 TH]
2604-488 Valve: [1.100 OD X 0.504 ID X 0.015 TH]
2604-489 Valve: [1.100 OD X 0.504 ID X 0.020 TH]
2604-684 Valve: [1.250 OD X 0.504 ID X 0.006 TH]
2604-685 Valve: [1.250 OD X 0.504 ID X 0.008 TH]
2604-686 Valve: [1.250 OD X 0.504 ID X 0.010 TH]
2604-687 Valve: [1.250 OD X 0.504 ID X 0.012 TH]
2604-688 Valve: [1.250 OD X 0.504 ID X 0.015 TH]
2604-490 Valve: [1.350 OD X 0.504 ID X 0.006 TH]
2604-491 Valve: [1.350 OD X 0.504 ID X 0.008 TH]
2604-492 Valve: [1.350 OD X 0.504 ID X 0.010 TH]
2604-493 Valve: [1.350 OD X 0.504 ID X 0.012 TH]
2604-494 Valve: [1.350 OD X 0.504 ID X 0.015 TH]
2604-495 Valve: [1.425 OD X 0.504 ID X 0.006 TH]
2604-496 Valve: [1.425 OD X 0.504 ID X 0.008 TH]
2604-497 Valve: [1.425 OD X 0.504 ID X 0.010 TH]
2604-498 Valve: [1.425 OD X 0.504 ID X 0.012 TH]
2604-499 Valve: [1.425 OD X 0.504 ID X 0.015 TH]
2604-500 Valve: [1.600 OD X 0.504 ID X 0.006 TH]
2604-501 Valve: [1.600 OD X 0.504 ID X 0.008 TH]
2604-502 Valve: [1.600 OD X 0.504 ID X 0.010 TH]
2604-503 Valve: [1.600 OD X 0.504 ID X 0.012 TH]
2604-504 Valve: [1.600 OD X 0.504 ID X 0.015 TH]

11
Double Bleed Shims (DB)
Single Bleed Shims (DB)
Fraction/Decimal
Conversion Chart
Drill Bit Sizes
(Number) Chart
AC PN Description
3603-342 Valve: DB 3 PORT (1.30" OD X .375" ID .004" THK.)
3603-343 Valve: DB 3 PORT (1.30" OD X .375" ID .006" THK.)
3603-344 Valve: DB 3 PORT (1.30" OD X .375" ID .008" THK.)
3603-345 Valve: DB 3 PORT (1.30" OD X .375" ID .010" THK.)
3603-346 Valve: DB 3 PORT (1.30" OD X .375" ID .012" THK.)
3603-347 Valve: DB 3 PORT (1.30" OD X .375" ID .015" THK.)
3603-348 Valve: DB 3 PORT (1.30" OD X .375" ID .020" THK.)
3603-481 Valve: DB 4 PORT (1.60" OD X .502" ID .004" THK.)
3603-482 Valve: DB 4 PORT (1.60" OD X .502" ID .006" THK.)
3603-483 Valve: DB 4 PORT (1.60" OD X .502" ID .008" THK.)
3603-484 Valve: DB 4 PORT (1.60" OD X .502" ID .010" THK.)
3603-485 Valve: DB 4 PORT (1.60" OD X .502" ID .012" THK.)
3603-486 Valve: DB 4 PORT (1.60" OD X .502" ID .015" THK.)
3603-487 Valve: DB 4 PORT (1.60" OD X .502" ID .020" THK.)
AC PN Description
3603-469 Valve: SB 3 PORT (1.30" OD X .375" ID .004" THK.)
3603-470 Valve: SB 3 PORT (1.30" OD X .375" ID .006" THK.)
4604-038 Valve: SB 3 PORT (1.30" OD X .375" ID .008" THK.)
3603-471 Valve: SB 3 PORT (1.30" OD X .375" ID .010" THK.)
3603-472 Valve: SB 3 PORT (1.30" OD X .375" ID .012" THK.)
3603-473 Valve: SB 3 PORT (1.30" OD X .375" ID .015" THK.)
3603-474 Valve: SB 3 PORT (1.30" OD X .375" ID .020" THK.)
3603-475 Valve: SB 4 PORT (1.60" OD X .502" ID .004" THK.)
3603-410 Valve: SB 4 PORT (1.60" OD X .502" ID .006" THK.)
3603-476 Valve: SB 4 PORT (1.60" OD X .502" ID .005" THK.)
3603-477 Valve: SB 4 PORT (1.60" OD X .502" ID .010" THK.)
3603-478 Valve: SB 4 PORT (1.60" OD 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 = .515625
1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875
3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125
1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375 39/64 = .609375
5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625 41/64 = .640625
3/4 = .750 11/16 = .6875 11/32 = .34375 11/64 = .171875 43/64 = .671875
7/8 = .875 13/16 = .8125 13/32 = .40625 13/64 = .203125 45/64 = .703125
— 15/16 = .9375 15/32 = .46875 15/64 = .234370 47/64 = .734375
— — 17/32 = .53125 17/64 = .265625 49/64 = .765625
— — 19/32 = .59375 19/64 = .296875 51/64 = .796875
— — 21/32 = .65625 21/64 = .328125 53/64 = .828125
— — 23/32 = .71875 23/64 = .359375 55/64 = .859375
— — 25/32 = .78125 25/64 = .390625 57/64 = .890625
— — 27/32 = .84375 27/64 = .421875 59/64 = .921875
— — 29/32 = .90625 29/64 = .453125 61/64 = .953125
— — 31/32 = .96875 31/64 = .484375 63/64 = .984375
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
No.
Size of
Drill in
Inches
1.2280 21 .1590 41 .0960 61 .0390
2.2210 22 .1570 42 .0935 62 .0380
3.2130 23 .1540 43 .0890 63 .0370
4.2090 24 .1520 44 .0860 64 .0360
5.2055 25 .1495 45 .0820 65 .0350
6.2040 26 .1470 46 .0810 66 .0330
7.2010 27 .1440 47 .0785 67 .0320
8.1990 28 .1405 48 .0760 68 .0310
9.1960 29 .1360 49 .0730 69 .0292
10 .1935 30 .1285 50 .0700 70 .0280
11 .1910 31 .1200 51 .0670 71 .0260
12 .1890 32 .1160 52 .0635 72 .0250
13 .1850 33 .1130 53 .0595 73 .0240
14 .1820 34 .1110 54 .0550 74 .0225
15 .1800 35 .1100 55 .0520 75 .0210
16 .1770 36 .1065 56 .0465 76 .0200
17 .1730 37 .1040 57 .0430 77 .0180
18 .1695 38 .1015 58 .0420 78 .0160
19 .1660 39 .0995 59 .0410 79 .0145
20 .1610 40 .0980 60 .0400 80 .0135

12
MM/IN. Conversion Chart
mm in. mm in. mm in. mm in.
.01 .00039 .51 .02008 1.03937 51 2.00787
.02 .00079 .52 .02047 2.07874 52 2.04724
.03 .00118 .53 .02087 3.11811 53 2.08661
.04 .00157 .54 .02126 4.15748 54 2.12598
.05 .00197 .55 .02165 5.19685 55 2.16535
.06 .00236 .56 .02205 6.23622 56 2.20472
.07 .00276 .57 .02244 7.27559 57 2.24409
.08 .00315 .58 .02283 8.31496 58 2.28346
.09 .00354 .59 .02323 9.35433 59 2.32283
.10 .00394 .60 .02362 10 .39370 60 2.36220
.11 .00433 .61 .02402 11 .43307 61 2.40157
.12 .00472 .62 .02441 12 .47244 62 2.44094
.13 .00512 .63 .02480 13 .51181 63 2.48031
.14 .00551 .64 .02520 14 .55118 64 2.51968
.15 .00591 .65 .02559 15 .59055 65 2.55905
.16 .00630 .66 .02598 16 .62992 66 2.59842
.17 .00669 .67 .02638 17 .66929 67 2.63779
.18 .00709 .68 .02677 18 .70866 68 2.67716
.19 .00748 .69 .02717 19 .74803 69 2.71653
.20 .00787 .70 .02756 20 .78740 70 2.75590
.21 .00827 .71 .02795 21 .82677 71 2.79527
.22 .00866 .72 .02835 22 .86614 72 2.83464
.23 .00906 .73 .02874 23 .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 1.10236 78 3.07086
.29 .01142 .79 .03110 29 1.14173 79 3.11023
.30 .01181 .80 .03150 30 1.18110 80 3.14960
.31 .01220 .81 .03189 31 1.22047 81 3.18897
.32 .01260 .82 .03228 32 1.25984 82 3.22834
.33 .01299 .83 .03268 33 1.29921 83 3.26771
.34 .01339 .84 .03307 34 1.33858 84 3.30708
.35 .01378 .85 .03346 35 1.37795 85 3.34645
.36 .01417 .86 .03386 36 1.41732 86 3.38582
.37 .01457 .87 .03425 37 1.45669 87 3.42519
.38 .01496 .88 .03465 38 1.49606 88 3.46456
.39 .01535 .89 .03504 39 1.53543 89 3.50393
.40 .01575 .90 .03543 40 1.57480 90 3.54330
.41 .01614 .91 .03583 41 1.61417 91 3.58267
.42 .01654 .92 .03622 42 1.65354 92 3.62204
.43 .01693 .93 .03661 43 1.69291 93 3.66141
.44 .01732 .94 .03701 44 1.73228 94 3.70078
.45 .01772 .95 .03740 45 1.77165 95 3.74015
.46 .01811 .96 .03780 46 1.81102 96 3.77952
.47 .01850 .97 .03819 47 1.85039 97 3.81889
.48 .01890 .98 .03858 48 1.88976 98 3.85826
.49 .01929 .99 .03898 49 1.92913 99 3.89763
.50 .01969 1.0 .03937 50 1.96850 100 3.93700

13
Wiring Diagram - Hood
Harness
(p/n 1686-706) - Cross Country
0748-009

14
NOTES

Wiring Diagram (Ignition/Main)
(Harness p/n 1686-732)
0747-813
15

16