Arctic Cat ZR4000 User manual

www.arcticcat.com
SERVICE MANUAL
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1
ZR/XF/M 4000/6000/8000
TABLE OF CONTENTS
General Information/Foreword ............................................... 2
Snowmobile Identification ........................................................ 2
Recommended Gasoline and Oil ............................................. 2
Engine Break-In ....................................................................... 3
Drive Belt Break-In ................................................................... 3
Genuine Parts .......................................................................... 3
Varying Altitude Operation ....................................................... 3
Preparation For Storage........................................................... 5
Preparation After Storage ........................................................ 5
After Break-In Checkup/Checklist ............................................ 6
Engine Specifications............................................................... 7
Crankshaft Runout/Repair Specifications ................................ 7
Electrical Specifications ........................................................... 9
Arctic Power Valve (APV) System Specifications..................... 8
Drive Clutch/Driven Clutch-Related Specifications ................ 10
Drive System Specifications................................................... 10
Drive System Components .................................................... 10
Chain Case Performance Calibrations................................... 10
Track Specifications ............................................................... 13
Suspension Specifications ..................................................... 13
Torque Conversions ............................................................... 13
Torque Specifications ............................................................. 14
Steering and Body ................................................................. 15
Steering Post (ZR/XF)............................................................ 15
Steering Post (XF HC) ........................................................... 16
Steering Post (M) ................................................................... 19
Ski (ZR/XF) ............................................................................ 22
Ski (XF HC/M) ........................................................................ 23
Ski Wear Bar .......................................................................... 23
Spindle (ZR/XF) ..................................................................... 24
Spindle (XF HC/M) ................................................................. 24
Steering Tie Rod .................................................................... 25
Ski Alignment ......................................................................... 26
A-Arms (ZR/XF) ..................................................................... 28
A-Arms (XF HC/M)................................................................. 29
Ski Shock Absorber................................................................ 30
Sway Bar (ZR/XF) .................................................................. 31
Front Bumper ......................................................................... 31
Seat Assembly (ZR/XF/M STD) ............................................. 31
Seat Assembly (M Sno Pro/HCR/LTD)................................... 32
Taillight/Brakelight Assembly.................................................. 32
Rear Bumper/Snowflap .......................................................... 33
Windshield/Console/ Headlight .............................................. 33
Headlight Bulb........................................................................ 34
Adjusting Headlight Aim ........................................................ 34
Engine..................................................................................... 36
Engine Removing/Installing - 4000 ........................................36
Assembly Schematic - 4000................................................... 40
Engine Removing/Installing - 6000 ........................................42
Assembly Schematic - 6000................................................... 48
Engine Removing/Installing - 8000 ........................................50
Assembly Schematic - 8000................................................... 56
Engine Servicing - 4000......................................................... 58
Engine Servicing - 6000......................................................... 73
Engine Servicing - 8000......................................................... 87
Troubleshooting Engine........................................................ 104
Engine-Related Items........................................................... 106
Water Pump - 4000 .............................................................. 106
Water Pump - 6000 .............................................................. 109
Water Pump - 8000 .............................................................. 112
Pressure Testing Engine ...................................................... 115
Liquid Cooling System ......................................................... 115
Cooling 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/Codes (4000)................................. 126
Self-Diagnostic System/Codes (6000)................................. 127
Self-Diagnostic System/Codes (8000)................................. 127
Fuel Pressure Regulator...................................................... 128
Throttle Body Assembly....................................................... 128
Throttle Cable ...................................................................... 129
Fuel Filter (6000) ................................................................. 130
Fuel Pump ........................................................................... 130
Troubleshooting ................................................................... 132
Oil-Injection Pump (4000/8000)........................................... 133
Electric Oil Pump (6000)...................................................... 134
Gas Tank ............................................................................. 135
Electrical Systems ...............................................................137
Ignition System .................................................................... 137
Throttle Position Sensor ...................................................... 138
Electrical Resistance Tests.................................................. 139
Testing Electric Oil Pump (6000) ......................................... 141
Testing Voltage Regulator.................................................... 141
Chassis Control Unit (CCU)/Codes (4000) .......................... 142
Testing Oil Level Sensor ...................................................... 142
Testing Fuel Gauge Sender................................................. 143
Emergency Stop Switch ...................................................... 143
Starter Relay Solenoid......................................................... 143
Fuse..................................................................................... 144
Ignition Switch ..................................................................... 144
Starter Motor........................................................................ 144
Troubleshooting Electric Start.............................................. 149
Ignition Timing ..................................................................... 149
Brakelight Switch ................................................................. 150
Headlight Dimmer Switch .................................................... 150
Testing Handlebar Warmer Elements ................................. 151
Testing Thumb Warmer Element ......................................... 151
Testing Handlebar Warmer/Thumb Warmer Switch ............ 151
Testing Speedometer Sensor .............................................. 152
Testing Shift Switch ............................................................. 152
Testing Servomotor/Potentiometer ...................................... 152
Troubleshooting Servomotor................................................ 154
Voltage/Resistance Chart - Air Temperature (8000) ............ 156
Voltage/Resistance Chart - Air Temperature (6000) ............ 156
Voltage/Resistance Chart - Coolant Temperature ............... 157
Drive Train/Track/Brake Systems .......................................158
Drive Belt ............................................................................. 158
Drive Clutch ......................................................................... 159
Driven Clutch ....................................................................... 162
Drive Clutch/Driven Clutch................................................... 168
Drive Train............................................................................ 170
Drive Sprockets ................................................................... 175
Track Tension....................................................................... 177
Track Alignment ................................................................... 178
Brake System ...................................................................... 179
Brake Lever/Master Cylinder Assembly............................... 183
Troubleshooting Hydraulic Brake System ............................ 185
Troubleshooting Track.......................................................... 185
Troubleshooting Drive Clutch/Driven Clutch ........................ 186
Suspension...........................................................................187
Suspension Setup Basics .................................................... 187
Servicing Suspension .......................................................... 193
FOX Air Shocks ................................................................... 204
Servicing IFP Shock ............................................................ 204

2
General
Information/Foreword
NOTE: General specifications for each 2016 Arctic
Cat Snowmobile can be accessed from the Arctic Cat
Cat Tracker Dealer Communication System online.
NOTE: Some illustrations and photographs used in
this section are used for clarity purposes only and are
not designed to depict actual conditions.
This Arctic Cat Service Manual contains service and main-
tenance information for certain Model Year 2016 Arctic
Cat Snowmobiles (see cover). The manual is designed to
aid service personnel in service-oriented applications.
This manual is divided into sections. The sections cover
specific snowmobile components or systems and, in
addition to the standard service procedures, includes
assembling, disassembling, and inspecting instructions.
When using this manual as a guide, the technician should
use discretion as to how much disassembly is needed to
correct any given condition.
The service technician should become familiar with the
operation and construction of the components or systems
by carefully studying the complete manual. This will
assist the service technician in becoming more aware of
and efficient with servicing procedures. Such efficiency
not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat publications and snowmobile decals dis-
play the words Warning, Caution, 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 snowmo-
bile-related damage. Follow the directive because it deals
with the possibility of damaging part or parts of the
snowmobile. The symbol NOTE: identifies supple-
mentary information worthy of particular attention.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs and 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.
All materials and specifications are subject to change
without notice.
Product Service and Warranty Department
Arctic Cat Inc.
Snowmobile Identification
The Arctic Cat Snowmobile has two important identifica-
tion numbers. The Vehicle Identification Number (VIN)
is stamped into the tunnel near the right-side footrest.
The decal also displays pertinent production information.
The Engine Serial Number (ESN) is stamped into the
crankcase of the engine.
These numbers are required to complete warranty claims prop-
erly. No warranty will be allowed by Arctic Cat if the engine
serial number or VIN is removed or mutilated in any way.
Recommended Gasoline
and Oil
RECOMMENDED GASOLINE
6000/8000
The recommended gasoline to use is 91 octane (mini-
mum).
NOTE: If a situation arises in which 91 octane gaso-
line is not available, 87 octane gasoline can be substi-
tuted; however, do not prolong the usage of 87 octane
gasoline as it will cause poor engine performance.
In many areas, oxygenates are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol are
acceptable gasolines.
4000
The recommended gasoline to use is 87 octane regular
unleaded. In many areas, oxygenates are added to the
gasoline. Oxygenated gasolines containing up to 10%
ethanol are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED OIL
The recommended oil to use in the oil-injection system is
either Arctic Cat C-Tec2 for the 6000 or Arctic Cat APV
Synthetic 2-Cycle Oil for the 4000/8000. These oils are
specially formulated to be used either as an injection oil
or as a pre-mix oil (for break-in) and meets all of the
lubrication requirements of the Arctic Cat snowmobile
engine.
CAUTION
Do not use white gas or gasoline containing methanol.
Only Arctic Cat approved gasoline additives should be
used.
CAUTION
Any oil used in place of the recommended oil may
cause serious damage.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage.

3
Engine Break-In
4000/8000
The Arctic Cat engine (when new or rebuilt) requires a
short break-in period before the engine is subjected to
heavy load conditions. Arctic Cat requires that the first
tankful of fuel be premixed at a 100:1 ratio in all
oil-injection models.
During the break-in period, a maximum of 1/2 throttle is
recommended; however, brief full-throttle accelerations
and variations in driving speeds contribute to good
engine break-in.
6000
The Arctic Cat engine (when new or rebuilt) requires a
short break-in period before the engine is subjected to
heavy load conditions.
When the snowmobile is new (0 hours), an addition to
the increased fuel and oil ratio, the ECM will limit the
engine to 6500 RPM for the first 18 minutes of the
engine's run time. After the first 18 minutes, the rev limit
will be eliminated but a greater fuel and oil ratio will con-
tinue through the first two hours of engine run time.
Premixing fuel and oil during the break in period is not
required. With the oil delivery control strategy of the
electronic oil pump, the pump will automatically com-
pensate and deliver a richer fuel-to-oil ratio during the
engine break-in period.
Some customers may choose to pre-mix the first tank and
if this is the case, a pre-mix ratio of 100:1 is acceptable.
A pre-mix ratio of 100:1 combined with the richer
fuel/oil delivered from the electronic oil pump during
break-in may cause additional smoke at start up and idle.
During the break-in period, a maximum of 1/2 throttle
(with varying throttle positions) is recommended; how-
ever, brief full-throttle accelerations and variations in
driving speeds contribute to good engine break-in.
Drive Belt Break-In
Drive belts require a break-in period of 25 miles. Drive
the snowmobile for 25 miles at 3/4 throttle or less. By
revving the engine up and down (but not exceeding 60
mph), the exposed cord on the side of a new belt will be
worn down. This will allow the drive belt to gain its opti-
mum flexibility and will extend drive belt life.
NOTE: Before starting the snowmobile in extremely
cold temperatures, the drive belt should be removed
and warmed up to room temperature. Once the drive
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, use only genuine
Arctic Cat parts. They are precision-made to ensure high
quality and correct fit.
Varying Altitude Operation
Operating a snowmobile at varying altitudes requires
recalibration of drive system components. Consult the
appropriate specification sheet on Cat Tracker Online.
Following are basic altitude theories for clutching,
engine, suspension, and track.
CLUTCHING
On a normally-aspirated engine as altitude changes,
engine horsepower changes with it. As you go up in alti-
tude, the engine loses horsepower. Because of this, the
continuously variable transmission (CVT) system needs
to be calibrated to compensate for the horsepower loss.
At altitudes above 5000 ft, the engine loses peak horse-
power but will also lose horsepower at engagement
speed. For this reason, calibrating the drive system is
usually needed in order to attain acceptable performance.
Changing drive clutch engagement speed can be done
several ways. Some of the methods will affect other char-
acteristics of CVT operation, so you must be careful what
you change. Drive clutch springs are the most common
way to increase engagement speed; however, by simply
changing the cam arms to a lighter weight from the
heavier sea level cam arm, you will gain some engage-
ment speed.
The driven clutch will also play a part in CVT tuning for
high altitude operation. A steeper helix (torque bracket)
angle in the driven clutch will mean a quicker up-shift. A
shallower angle will mean a slower up-shift. If the
up-shift is too quick, due to a very steep helix, RPM will
be pulled down under the peak operating RPM of the
engine (where the horsepower is) and performance will
suffer. The engine may even bog.
CAUTION
DO NOT exceed the one (1) tankful limitation of a 100:1
gas/oil break-in mixture. Continuous use of a gas/oil
mixture could cause spark plug fouling and excessive
carbon buildup.
CAUTION
DO NOT exceed the one (1) tankful limitation of a 100:1
gas/oil break-in mixture. Continuous use of a gas/oil
mixture could cause spark plug fouling and excessive
carbon buildup.
CAUTION
Running the engine with the drive belt removed could
result in serious engine damage and drive clutch failure.

4
ENGINE
A normally aspirated engine will generate more horse-
power at sea level than it does at higher altitudes. The
reason is that the higher you go, less oxygen is available
for the engine to use during its combustion process. Less
oxygen means it needs less fuel to obtain the correct
air/fuel ratio to operate properly. This is why the fuel
ratio has to be recalibrated. High altitude engines operate
as though they have a lower compression ratio. This,
along with less oxygen and less fuel, means that the
engine generates less horsepower. All of these character-
istics will become more evident the higher the altitude.
SUSPENSION
The different riding styles of the individual operator, the
varying snow conditions, and the type of terrain are all
factors that affect the suspension at high altitude. Trail
riding versus powder snow riding versus combination
riding will all require different suspension settings.
The normal setting for front ski suspension is as little spring
pre-load tension as possible for powder snow riding allow-
ing the skis to float across the snow with the least amount
of resistance. Trail riding will require more spring tension
to carry the varying load more effectively. Many different
settings and spring tensions to consider exist when adjust-
ing for riding style and snow conditions.
The rear suspension has a number of spring settings that
produce different riding characteristics.
The front arm spring and shock will also affect the ride
and handling when either on a trail or in powder snow. A
strong spring setting on this shock will cause the snow-
mobile to tend to “dig” more when riding in the powder
snow rather than climbing up on top of the snow. But, it
will work more effectively when riding on a trail. A
softer spring setting will allow the front of the rear sus-
pension to collapse much quicker and change the angle of
the track to the snow. A more gradual angle will tend to
raise the snowmobile up on the snow rather than digging
into it.
Many possible variables and adjustments to the rear sus-
pension exist depending on snow conditions, riding style,
and type of terrain. These adjustments can be made to
individualize the snowmobile to the riding style of the
operator.
As snow cover and riding conditions change, several dif-
ferent adjustments can be made to change the ride and
handling characteristics for operator preference. Located
on the front suspension arm are limiter straps. They limit
the amount of “fallout” the front arm can have. These
straps may be adjusted in or out due to conditions and
riding style. The more the straps are brought up, the more
steering power the operator has due to the amount of ski
pressure.
Another adjustment that can be made on the rear suspen-
sion is the front arm shock spring tension. As trail condi-
tions change, the spring pre-load may be used to decrease
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 snow, the stiffer
spring pre-load will cause the front-end to “dig” and pos-
sibly take longer for it to plane off. Several different-rate
springs are available for different riding styles and terrain
conditions.
On the standard models, the front shock springs are also
individually adjustable for the terrain conditions and
driving style of the operator. The spring adjuster has been
set at the factory so the correct amount of threads are
exposed between the spring adjuster and the shock hous-
ing as an initial setting. Additional ski pressure can be
obtained by tightening the spring tension; ski pressure
can be decreased by relaxing spring tension. Springs with
different spring rates are available for operator choice
and snow conditions.
A limit exists as to how far you can pre-load the springs
before “coil bind” takes effect where the wire on the
spring actually runs into itself and causes binding. Equal
adjustments should be maintained on both sides of the
snowmobile. On the Sno Pro models with float shocks,
they are individually adjustable for the terrain conditions
and driving style of the operator. The shocks are preset at
the factory (see chart) as an initial setting; however, it is
possible to “fine tune” the shocks to match the operator’s
weight, riding style, and terrain conditions.
Checking and adjusting air pressure must be done at rid-
ing temperature (outside) and shocks are at full extension
with no weight on the shock. Also, it is advisable to
check air pressure when the outside temperature varies
more than 25°.
NOTE: Care should be taken to have equal pressure
in the ski shocks before operating the snowmobile.
Finally, track tension should be looked at to make sure
that it is within recommended specifications to affect the
efficiency of the snowmobile. On models with the torque
sensing link, the track is actually tightening as the sus-
pension moves through its range of motion causing the
track to sag in the middle and rub on the top part of the
rear suspension arm.
TRACK
Carefully matching the riding requirements to the type of
track will ensure the maximum use of all available engine
power. Lug height and track durometer are the two main
concerns when selecting a track for various riding styles.
Tracks exist with lug heights from 1.0” up to 3.0” to
accommodate various snow conditions. Generally, the
deeper the snow, the taller the lug. It must be noted that
the installation of any deep-lug track may reduce top end
speed and promote premature wear strip wear in marginal
snow conditions.
Initial Setting Chart
Model Front Shock
(Ski)
Front Arm
Shock
Rear Arm
Shock
XF/ZR Sno Pro 60 psi N/A N/A
XF HC/M Sno Pro 95 psi N/A 130 psi
M LTD 90 psi (Main
Chamber)
150 psi (Evol
Chamber)
50 psi (Main
Chamber)
125 psi (Evol
Chamber)
150 psi (Main
Chamber)
250 psi (Evol
Chamber)
ZR RR 100 psi (Main
Chamber) 200 psi
(Evol Chamber)
N/A N/A

5
Durometer is a measurement of how hard a rubber is. The
lugs on most tracks range between 60 and 85 durometer.
On the durometer scale, the higher the number, the harder
the lugs. For riding in deep powder snow, a softer durom-
eter track works best. The softer rubber allows the track
to “give” a little and pack the snow creating lift rather
than digging its way straight down. When hill-climbing,
the harder lug of an 80 durometer track works the best
due to penetrating the hard snow creating more bite.
Some tracks come with a dual durometer rating, such as a
track with a 80/60 durometer rating. The lugs on this track
are 80% 80 durometer rubber, and the top 20% is made of
the softer 60 durometer rubber. This track is designed to be
a good all-around track for riding mostly in deep powder
snow but can climb the occasional hard snow hill.
Preparation For Storage
Prior to storing the snowmobile, it must be properly ser-
viced to prevent corrosion and component deterioration.
1. Clean the seat cushion with a damp cloth and Arctic
Cat Vinyl Protectant.
2. Clean the snowmobile thoroughly by hosing dirt, oil,
grass, and other foreign matter from the skid frame,
tunnel, hood, and belly pan. Allow the snowmobile
to dry thoroughly. DO NOT get water into any part
of the engine.
3. Place the rear of the snowmobile up on a shielded
safety stand; then start the engine and allow to idle.
Spray an Engine Storage Preserver into the intakes
until the engine exhaust starts to smoke heavily or
until the engine starts to drop in RPM. Turn engine
off. Install the intake boots.
4. Plug the exhaust system outlet with a clean cloth.
5. With the ignition switch in the OFF position:
A. Disconnect the high tension leads from the spark
plugs; then remove the plugs, connect them to the
leads, and ground them on the cylinder heads.
B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum-based
oil into each spark plug hole and pull the recoil
starter handle slowly about 10 times.
C. Install the spark plugs and connect the high tension leads.
6. Fill the gas tank to its rated capacity; then add Arctic
Cat Fuel Stabilizer to the gas tank following direc-
tions on the container for the stabilizer/gasoline
ratio. Tighten the gas tank cap securely.
7. With the snowmobile level, check the lubricant level
in the chain case. If low, add chain lube through the
fill plug hole.
8. Remove the drive belt from the drive clutch/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 light oil to the upper steering post bushings and
to the shafts of the shock absorbers; then lubricate the
rear suspension with an all-temperature grease.
10. Tighten all nuts, bolts, and cap screws making sure all
calibrated nuts, bolts, and cap screws are tightened to
specifications. Make sure all rivets holding the compo-
nents together are tight. Replace all loose rivets.
11. Clean and polish the hood, console, and chassis with
Cat Cleaner. DO NOT USE SOLVENTS. THE PRO-
PELLENT WILL DAMAGE THE FINISH.
12. On electric start models, disconnect the battery
cables making sure to disconnect the negative cable
first; then clean the battery posts and cables.
13. If possible, store the snowmobile indoors. Raise the
track off the floor by blocking up the back end mak-
ing sure the snowmobile is secure. Loosen the track
adjusting bolts to reduce track tension. Cover the
snowmobile with a machine cover or a heavy, venti-
lated tarpaulin to protect it from dirt and dust.
14. If the snowmobile must be stored outdoors, position
the snowmobile out of direct sunlight; then block the
entire snowmobile off the ground making sure the
snowmobile is secure. Loosen the track adjusting
bolts to reduce track tension. Cover with a machine
cover or a heavy, ventilated tarpaulin to protect it
from dirt, dust, and rain.
Preparation After Storage
Taking the snowmobile out of storage and correctly pre-
paring it for another season will assure many miles and
hours of trouble-free snowmobiling. Arctic Cat recom-
mends the following procedure:
1. Clean the snowmobile thoroughly. Polish the exterior
of the snowmobile.
2. Clean the engine. Remove the cloth from the exhaust
system. Check exhaust system and air silencer for
obstructions.
3. Inspect all control wires and cables for signs of wear
or fraying. Replace if necessary. Use cable ties or
tape to route wires and cables away from hot or rotat-
ing parts.
CAUTION
Do not run the engine without the belt guard in place
and secured.
CAUTION
Never crank the engine over without grounding the
spark plugs. Damage to coils and/or ECM may result.
CAUTION
Sealed batteries require charging if left for extended
non-start periods. Arctic Cat recommends trickle
charging once a month. Follow the manufacturer’s
instructions and cautions.
CAUTION
Avoid storing in direct sunlight and using a plastic
cover as moisture may collect on the snowmobile caus-
ing corrosion.

6
4. Inspect the drive belt for cracks and tears. Check belt
specifications. Replace if damaged or worn. Install
the drive belt.
NOTE: If the old belt is worn but in reasonable con-
dition, retain it with the snowmobile as a spare in case
of emergency.
5. Adjust the throttle cable. Inspect all fuel hoses and
oil hoses for deterioration or cracks; replace if neces-
sary. Make sure all connections are tight.
6. Fill the oil-injection reservoir with the recommended
2-cycle oil; then inspect each spark plug. Replace,
gap, or clean as necessary.
NOTE: After prolonged storage on the 8000, Arctic
Cat recommends one tankful of 100:1 gas/oil mixture
be used in conjunction with the oil-injection system to
ensure proper lubrication.
7. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are tight-
ened to specifications.
8. If not done during preparation for storage, lubricate
the rear suspension with an all-temperature grease.
9. Check the coolant level and all coolant hoses and
connections for deterioration or cracks. Add properly
mixed coolant as necessary.
10. On electric start models, charge the battery; then
connect the battery cables making sure to connect the
positive cable first. Test the electric start system.
11. Inspect the entire brake system, all controls, head-
light, taillight, brake light, ski wear bars, and head-
light aim; adjust or replace as necessary.
12. Adjust the track to the proper tension and alignment.
After Break-In
Checkup/Checklist
Certain areas require adjustment after the break-in period
in order to obtain peak performance. These areas are the
following.
DRIVE BELT DEFLECTION — Drive belt deflection
is very important to the snowmobile. Even if it is checked
and is correct when the snowmobile is set up, it does
change (more so during the break-in period). This is
because the rubber engine mounts and the rubber 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 have too long of a drive belt. To
add to this, the drive belt wears and stretches. This some-
times leads to a reduction in low-end performance, and if
not corrected, can cause premature drive belt wear.
After the break-in period, drive belt deflection should be
checked according to the instructions given in the Drive
Train/Track/Brake Systems section of this manual.
DRIVE CLUTCH/DRIVEN CLUTCH
ALIGNMENT (OFFSET) — The alignment between
the drive clutch and driven clutch are set at the factory.
Normally, no adjustment is necessary; however, if prema-
ture drive belt wear or poor performance is experienced,
the drive clutch/driven clutch alignment must be
checked. See “Checking Offset” in the driven train sec-
tion in this manual.
TRACK TENSION AND ALIGNMENT — A certain
amount of stretch occurs on all tracks during the first 500
miles. The track must be inspected/adjusted after the first
50 to 100 miles to the specifications given in the Track
Specifications sub-section of this section and periodically
thereafter. If these adjustments aren’t performed, the
track may “derail” which leads to track and slide rail
damage.
Along with these major areas, other areas should be
checked and adjusted.
Below is a list of items to check after the break-in period.
The recommended mileage for this inspection is between
100 and 300 miles.
 Check drive belt deflection - drive clutch/driven
clutch alignment
 Adjust track tension and alignment
 Check throttle cable tension
 Check oil-injection pump adjustment (4000/8000)
 Check engine idle
 Check coolant level
 Check chain case lubricant level
 Check lights (high/low beam, brakelight)
 Check safety switch operation
 Check engine compartment for any rubbing com-
ponents
 Check steering hardware for tightness
 Check skid frame and A-arm mounting hardware
for tightness
 Check brake lever travel and adjustment
 Grease all lubrication points

7
Engine Specifications
4000
6000
8000
Crankshaft Runout/Repair
Specifications
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 is still supported
on the outer bearings using V blocks.
728-144A
NOTE: Measure in from the shaft end the specified
amount when checking runout at points D and F. When
checking runout in the center, place indicator on center
of bearing as shown at point E. Maximum runout at
any of the three measuring points is ± 0.002”.
6000
NOTE: The crankshaft must be supported on the
inner bearings using V blocks.
0747-810
ITEM
Engine Model Number AX50L9
Displacement 499 cc
Bore x Stroke 71 x 63
Compression Ratio 6.38:1
Cooling System Liquid
Ignition Timing (Engine Warm) 13° @ 2000 RPM
0.040”
Spark Plug (NGK) BR9EYA
Spark Plug Gap 0.028-0.031”
Piston Skirt/Cylinder Clearance 0.0031-0.0041”
Piston Ring End Gap 0.008-0.016”
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 0.315”
ITEM
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”
ITEM
Engine Model Number AB80L4
Displacement 794 cc
Bore x Stroke 85 x 70
Compression Ratio 6.62:1
Cooling System Liquid
Ignition Timing (Engine Warm) 16.5° @ 2000
RPM 0.072”
Spark Plug (NGK) BR9EYA
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”
Model A
± 0.006
B
± 0.006
C
± 0.015 G
Runout D
and F Point
± 0.002
4000 4.515” 2.618” 4.465” 1.062” D
0.196”
F
0.196”
8000 4.751” 2.519” 4.645” 1.181” D
0.196”
F
0.196”

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

9
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 voltage.
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
4000 (Normally Open Ignition)
Ignition Coil (Primary)
(Secondary)
0.24-0.36 ohm
6800-10,200 ohms
orange/black
high tension wire
orange/red
ground
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 80.8-121 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
Chassis Control Unit* 9-15 DC Volts red/blue (low power)
red/black (high power)
black (low power)
black (high power)
6000 (Normally Open Ignition)
Ignition Coil (Primary)
(Secondary)
0.24-0.36 ohm
5040-7560 ohms
black/white
high tension wire
white/blue
ground
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 11.4-12.6 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 (counterclockwise)
black/red (clockwise)
black/red (counterclockwise)
red/black (clockwise)
Voltage Regulator/Rectifier* 9-15 DC Volts red/blue black
8000 (Normally Open Ignition)
Ignition Coil (Primary)
(Secondary)
0.24-0.36 ohm
5040-7560 ohms
black/white
high tension wire
white/blue
ground
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 (counterclockwise)
black/red (clockwise)
black/red (counterclockwise)
red/black (clockwise)
Voltage Regulator/Rectifier* 9-15 DC Volts
9-15 AC Volts
red/blue
yellow
brown
brown
! WARNING
Most voltages generated by the ignition system are sufficient to interrupt pacemakers! All technicians, especially
those using pacemakers, must avoid contact with all electrical connections when pulling the recoil starter rope or
after the engine has been started.

10
Drive System
Specifications
Drive Clutch/Driven
Clutch-Related
Specifications
Drive System Components
A list of Drive System components that are available
through the Arctic Cat Service Parts Department can be
found in the Quick Reference Guide. This information
will be useful when doing any fine-tuning on the drive
system.
Chain Case Performance
Calibrations
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 4000 LXR 0-5000 Yellow/White 63g Black/Blue 42°/40° 0627-083 36-4000 81-8200 21T 49T 90
ZR 4000 RR 0-5000 Yellow/White 63g Black/White 44°/42° 0627-083 36-4000 81-8200 21T 49T 90
ZR 6000/XF 6000 0-5000 85/255 lb 66g 140/200 lb 48S ER3 0627-083 42-4600 81-8200 22T 48T 90
ZR 8000/XF 8000 0-5000 85/235 lb 72g 140/200 lb 66-49-.20 ER3 0627-084 36-4000 81-8200 21T 41T 86
XF 6000 High Country 0-3000 85/255 lb 66g 140/200 lb 48S ER3 0627-083 42-4600 81-8200 19T 50T 90
XF 8000 High Country 0-3000 85/235 lb 72g 140/200 lb 66-48-.20 ER3 0627-084 36-4000 81-8200 19T 50T 90
/M 6000 6-8000 85/255 lb 60g 180/240 lb 48S ER3 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 12.10” 1.500” None
4000 LXR 0644-246 12.10” 1.485” None
Drive
Sprocket
Gear
Ratio Ratio Chain Engine RPM
Top Btm 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000
Vehicle Speed (mph)
7 Tooth
(3.0" pitch)
19 50 0.380 90 52 54 56 58 59 61 63 64 66 68 69 71 73 74 76
21 49 0.429 90 59 61 63 65 67 69 71 73 74 76 78 80 82 84 86
20 46 0.435 88 60 62 64 66 68 70 72 74 75 77 79 81 83 85 87
23 51 0.451 92 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90
22 48 0.458 90 63 65 67 69 71 73 76 78 80 82 84 86 88 90 92
24 50 0.480 92 66 68 71 73 75 77 79 81 83 85 88 90 92 94 96
21 41 0.512 86 71 73 75 78 80 82 84 87 89 91 93 96 98 100 103
21 38 0.553 84 76 79 81 84 86 89 91 93 96 98 101 103 106 108 111
20 35 0.571 82 79 81 84 87 89 92 94 97 99 102 104 107 109 112 114
23 40 0.575 86 79 82 84 87 90 92 95 97 100 102 105 108 110 113 115
22 37 0.595 84 82 85 87 90 93 95 98 101 103 106 109 111 114 116 119
24 39 0.615 86 85 88 90 93 96 99 101 104 107 110 112 115 118 121 123
23 36 0.639 84 88 91 94 97 100 102 105 108 111 114 117 119 122 125 128
24 35 0.686 84 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137

11
8 Tooth
(2.86"
pitch)
19 50 0.380 90 57 59 61 63 65 66 68 70 72 74 76 77 79 81 83
21 49 0.429 90 64 67 69 71 73 75 77 79 81 83 85 87 89 91 94
20 46 0.435 88 65 67 70 72 74 76 78 80 82 84 86 89 91 93 95
23 51 0.451 92 68 70 72 74 77 79 81 83 85 88 90 92 94 96 98
22 48 0.458 90 69 71 73 76 78 80 82 84 87 89 91 93 96 98 100
24 50 0.480 92 72 75 77 79 81 84 86 88 91 93 95 98 100 102 105
21 41 0.512 86 77 80 82 84 87 89 92 94 97 99 102 104 107 109 112
21 38 0.553 84 83 86 88 91 94 97 99 102 105 107 110 113 115 118 121
20 35 0.571 82 86 89 91 94 97 100 103 105 108 111 114 116 119 122 125
23 40 0.575 86 86 89 92 95 98 100 103 106 109 112 114 117 120 123 126
22 37 0.595 84 89 92 95 98 101 104 107 110 112 115 118 121 124 127 130
24 39 0.615 86 93 96 99 101 104 107 110 113 116 119 122 125 128 131 134
23 36 0.639 84 96 99 102 105 108 112 115 118 121 124 127 130 133 136 139
24 35 0.686 84 103 106 110 113 116 120 123 126 130 133 136 140 143 146 150
8 Tooth
(3.0" pitch)
19 50 0.380 90 60 62 64 66 68 70 72 73 75 77 79 81 83 85 87
21 49 0.429 90 68 70 72 74 76 79 81 83 85 87 89 92 94 96 98
20 46 0.435 88 69 71 73 75 77 80 82 84 86 88 91 93 95 97 100
23 51 0.451 92 71 73 76 78 80 83 85 87 89 92 94 96 99 101 103
22 48 0.458 90 72 75 77 79 82 84 86 89 91 93 96 98 100 103 105
24 50 0.480 92 76 78 81 83 85 88 90 93 95 98 100 103 105 107 110
21 41 0.512 86 81 83 86 89 91 94 96 99 102 104 107 109 112 115 117
21 38 0.553 84 87 90 93 96 98 101 104 107 110 112 115 118 121 124 127
20 35 0.571 82 90 93 96 99 102 105 108 110 113 116 119 122 125 128 131
23 40 0.575 86 91 94 97 99 102 105 108 111 114 117 120 123 126 129 132
22 37 0.595 84 94 97 100 103 106 109 112 115 118 121 124 127 130 133 136
24 39 0.615 86 97 100 103 106 110 113 116 119 122 125 128 132 135 138 141
23 36 0.639 84 101 104 107 111 114 117 120 124 127 130 133 137 140 143 146
24 35 0.686 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 93
20 46 0.435 88 65 67 69 71 73 75 77 79 82 84 86 88 90 92 94
23 51 0.451 92 67 69 72 74 76 78 80 82 85 87 89 91 93 95 98
22 48 0.458 90 68 71 73 75 77 79 82 84 86 88 90 93 95 97 99
24 50 0.480 92 72 74 76 78 81 83 85 88 90 92 95 97 99 102 104
21 41 0.512 86 76 79 81 84 86 89 91 94 96 99 101 103 106 108 111
21 38 0.553 84 82 85 88 90 93 96 98 101 104 106 109 112 114 117 120
20 35 0.571 82 85 88 91 93 96 99 102 104 107 110 113 115 118 121 124
23 40 0.575 86 86 88 91 94 97 100 102 105 108 111 113 116 119 122 124
22 37 0.595 84 89 91 94 97 100 103 106 109 112 114 117 120 123 126 129
24 39 0.615 86 92 95 98 101 104 107 109 112 115 118 121 124 127 130 133
23 36 0.639 84 95 98 101 104 108 111 114 117 120 123 126 129 132 135 138
24 35 0.686 84 102 106 109 112 115 119 122 125 129 132 135 138 142 145 148
9 Tooth
(2.86"
pitch)
19 50 0.380 90 64 66 68 71 73 75 77 79 81 83 85 87 89 91 93
21 49 0.429 90 73 75 77 80 82 84 87 89 91 94 96 98 101 103 105
20 46 0.435 88 74 76 78 81 83 85 88 90 93 95 97 100 102 104 107
23 51 0.451 92 76 79 81 84 86 89 91 94 96 98 101 103 106 108 111
22 48 0.458 90 78 80 83 85 88 90 93 95 98 100 103 105 108 110 113
24 50 0.480 92 81 84 86 89 92 94 97 100 102 105 107 110 113 115 118
21 41 0.512 86 87 89 92 95 98 101 103 106 109 112 115 117 120 123 126
21 38 0.553 84 93 97 100 103 106 109 112 115 118 121 124 127 130 133 136
20 35 0.571 82 97 100 103 106 109 112 115 118 122 125 128 131 134 137 140
23 40 0.575 86 97 100 104 107 110 113 116 119 122 126 129 132 135 138 141
22 37 0.595 84 101 104 107 110 114 117 120 123 127 130 133 136 140 143 146
24 39 0.615 86 104 107 111 114 118 121 124 128 131 134 138 141 144 148 151
23 36 0.639 84 108 112 115 119 122 126 129 132 136 139 143 146 150 153 157
24 35 0.686 84 116 120 123 127 131 135 138 142 146 150 153 157 161 165 168
Drive
Sprocket
Gear
Ratio Ratio Chain Engine RPM

12
Drive
Sprocket
Gear
Ratio Ratio Chain Engine RPM
Top Btm 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000
Vehicle Speed (mph)
9 Tooth
(3.0" pitch)
19 50 0.380 88 67 70 72 74 76 78 80 83 85 87 89 91 94 96 98
21 49 0.429 90 76 79 81 83 86 88 91 93 96 98 101 103 105 108 110
20 46 0.435 88 77 80 82 85 87 90 92 95 97 100 102 105 107 110 112
23 51 0.451 92 80 83 85 88 90 93 96 98 101 103 106 108 111 114 116
22 48 0.458 90 81 84 87 89 92 94 97 100 102 105 108 110 113 115 118
24 50 0.480 92 85 88 91 93 96 99 102 104 107 110 113 115 118 121 124
21 41 0.512 86 91 94 97 100 103 106 108 111 114 117 120 123 126 129 132
21 38 0.553 84 98 101 104 108 111 114 117 120 123 127 130 133 136 139 142
20 35 0.571 82 101 105 108 111 114 118 121 124 128 131 134 137 141 144 147
23 40 0.575 86 102 105 109 112 115 118 122 125 128 132 135 138 142 145 148
22 37 0.595 84 106 109 112 116 119 123 126 129 133 136 140 143 146 150 153
24 39 0.615 86 109 113 116 120 123 127 130 134 137 141 144 148 151 155 159
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
(2.52"
pitch)
19 50 0.380 90 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91
21 49 0.429 90 71 73 76 78 80 82 85 87 89 92 94 96 98 101 103
20 46 0.435 88 72 74 77 79 81 84 86 88 91 93 95 98 100 102 105
23 51 0.451 92 75 77 80 82 84 87 89 92 94 96 99 101 104 106 108
22 48 0.458 90 76 78 81 83 86 88 91 93 96 98 100 103 105 108 110
24 50 0.480 92 80 82 85 87 90 92 95 97 100 103 105 108 110 113 115
21 41 0.512 86 85 88 90 93 96 99 101 104 107 109 112 115 118 120 123
21 38 0.553 84 92 94 97 100 103 106 109 112 115 118 121 124 127 130 133
20 35 0.571 82 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137
23 40 0.575 86 95 98 101 104 108 111 114 117 120 123 126 129 132 135 138
22 37 0.595 84 98 102 105 108 111 114 118 121 124 127 130 133 137 140 143
24 39 0.615 86 102 105 108 112 115 118 122 125 128 132 135 138 141 145 148
23 36 0.639 84 106 109 113 116 119 123 126 130 133 137 140 143 147 150 154
24 35 0.686 84 114 117 121 125 128 132 136 139 143 147 150 154 158 161 165

13
Track Specifications
NOTE: The track tension on all models should be 20
lb @ 2 inches.
Suspension Specifications
SPRINGS
0730-218
IFP SHOCK ABSORBERS
Below is a list of IFP shock absorbers used on the front
and rear suspensions of Arctic Cat snowmobiles. If
replacing a shock absorber, always select a shock
absorber with the same length, both collapsed and
extended.
Torque Conversions
Track Tension
Model Length Lug
Height Setup After Break-in
ZR LXR 129" 1" 2-2.25” 2-2.25"
ZR Sno Pro/El Tigre 129" 1.25" 2-2.25” 2-2.25"
M SE 141”/153"/162" 2.25" 2-2.25" 2-2.25"
M Sno Pro/HCR 153"/162" 2.6" 2-2.25” 2-2.25"
M LTD 153”/162” 3.0” 2-2.25” 2-2.25”
XF Standard 137" 1.25" 2-2.25” 2-2.25"
XF CrossTrek 137” 1.6” 2-2.25” 2-2.25”
XF HC 141" 2.25" 2-2.25” 2-2.25"
XF Sno Pro 141" 1.5" 2-2.25” 2-2.25"
SKI SHOCK
Model Wire
Diameter
Free
Length Rate Coils Tab
ZR/XF 0.312” 13.00” 95 lb/in. 10 NO
FRONT ARM
Model Wire
Diameter
Free
Length Rate Coils Tab
ZR/XF 0.312” 8.25” 90/250
lb/in.
9.8 NO
M SE 0.295” 7.75” 110 lb/in. 7.0 NO
REAR ARM
Model Wire
Diameter
Free
Length Rate Coils Tab
M SE/XF 0.375” 13.00” 175 lb/in. 10.5 NO
REAR ARM (See Illustration Below)
Model
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”
FRONT ARM
Model Collapsed
Length
Extended
Length Stroke Piston Depth
ZR 8.14” 11.74” 3.59” 4.50”
XF/XF HC/M SE 8.55” 12.50” 3.94” 4.91”
REAR ARM
Model Collapsed
Length
Extended
Length Stroke Piston Depth
ZR 9.89” 13.98” 4.09” 5.70”
XF 137” 10.32” 15.12” 4.80” 6.13”
M SE 10.89” 16.05” 5.16” 6.15”
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

14
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
* w/Green Loctite #609
** w/Blue Loctite #243
*** w/Oil
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
Ring Gear* Drive Clutch 22
Spider (Team) Movable Sheave 250
Cam Arm Pin Lock Nut Cam Arm Pin 11
Cam Arm Lock Nut (Team) Cam Arm Screw 50 in.-lb
Cam Arm Set Screw Cam Arm 19 in.-lb
Driven Clutch (Team) Driven Shaft 60
Driven Clutch** (Arctic Cat) Driven Shaft 20
Movable Sheave* (Arctic Cat) Torque Bracket 27
Movable Sheave* (Team) Torque Bracket 120 in.-lb
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
Ski Spindle 35
Ski Wearbar 8
Ski Ski Handle 54 in.-lb
Handlebar Adjuster Block 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) (XF HC/M) Chassis 9
A-Arm (Upper) (ZR/XF) Chassis 23
A-Arm (Lower) Chassis (Front) 65
A-Arm (Lower) Chassis (Rear) 45
A-Arm (Upper) (ZR/XF) Spindle 45
A-Arm (Upper) (XF HC/M) Spindle 23
A-Arm (Lower) Spindle 45
Shock Absorber (ZR, XF) Spindle 32
Shock Absorber (ZR, XF) Chassis 32
Shock Absorber (XF HC/M) Spindle 24
Shock Absorber (XF HC/M) Chassis 24
Sway Bar Link A-Arm/Sway Bar Link 23
Sway Bar Mounting Bracket Chassis 9
REAR SUSPENSION
Item Secured to Torque
ft-lb
M/XF 141”
Wear Strip Rail 50 in.-lb
End Cap/Rail Cap Wheel (M) Rail 20
Mounting Block Rail 12
Rear Wheel Axle Rail 34
Rear Arm Rail 20
Idler Arm Rear Arm 20
Front Shock Rail 50
Rear Shock Front Arm/Idler Arm 24
Rail Support Rail 20
Front Shock Front Arm 24
Limiter Strap Rail Support 72 in.-lb
Rail Rail Brace 12
Rear Tri Hub Wheel Rear Tri Hub Wheel 50 in.-lb
Rear Shock Link Front Arm/Idler Arm 24
Front Arm** Rail 52
Skid Frame** Tunnel 45
ZR/XF 137”
Wear Strip Rail 50 in.-lb
End Cap Rail 80 in.-lb
Mounting Block Rail 12
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

15
Steering and Body
This section has been organized into sub-sections for ser-
vicing steering and body components; however, some
components may vary from model to model. The techni-
cian should use discretion and sound judgment when
removing and installing components.
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when servicing the steering and body systems.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Steering Post (ZR/XF)
REMOVING
1. Remove the hairpin clip from the pin located at the
front of the access panel. Move the panel up and off
the pin; then swing the panel all the way out and
unhinge the panel from the lower console.
2. Remove all six torx-head screws securing the hood.
0746-793
3. Locate the hood harness connector (located under the
center vent and between the intake vents) and unplug
the connector; 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 chamber.
5. Remove the push rivets securing the right-side steer-
ing boot to the chassis. This allows access to the two
nuts securing the bottom of the steering post.
XM134A
6. Remove the nut (A) securing the bottom of the exist-
ing steering post to the steering stop bracket; then
remove the nut (B) securing the steering tie rod
assembly to the steering post. Discard both nuts.
SNO-2221A
7. Remove the cap screws and handlebar caps securing
the handlebar to the top of the handlebar riser; then
remove the two nuts securing the top of steering post
to the chassis. Account for both steering post blocks
and retaining plate.
SNO-357
8. Carefully remove the steering post from the snow-
mobile.
INSTALLING
1. Install steering post into position and secure to the
steering stop bracket with a new M10 nut. Be sure to
align the steering post ball joint alignment tab
with the steering stop bracket. Tighten to 43 ft-lb.
Description p/n
Handlebar Stand 5639-152
Steering Post Stand 5639-946

16
SNO-2218
2. Secure the tie rod assembly to the steering post using
a new M10 nut. Be sure to align the tie rod ball
joint alignment tab with the steering post. Tighten
to 35 ft-lb.
SNO-2219
3. Secure the right-side steering boot to the chassis
using the existing push rivets.
XM134A
4. Secure the top of the steering post to the steering
support using the existing retaining plate and nuts.
Tighten to 96 in.-lb.
5. Install the handlebar riser and handlebar to the top of
the steering post and secure using the existing caps
and screws. 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 and connect
the hood harness connector.
8. Secure the hood with the six torx-head screws and
tighten securely.
9. Install the access panels onto the lower console; then
close the access panels and secure with the clip.
Steering Post (XF HC)
REMOVING
1. Remove the hairpin clip from the pin located at the
front of the access panel; then unscrew the thumb
screw. Move the panel up and off the pin; then swing
the panel all the way out and unhinge the panel from
the lower console.
0746-800
2. Remove all six torx-head screws securing the hood.

17
0746-793
3. Locate the hood harness connector (located under the
center vent between the intake vents) and unplug the
connector; 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 chamber.
5. Remove the push rivets securing the right-side steer-
ing boot to the chassis. This allows access to the two
nuts securing the bottom of the steering post.
XM134A
6. Remove the nut (A) securing the bottom of the exist-
ing steering post to the steering stop bracket; 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 securing the tie
rod link to the secondary steering post; then remove
the two machine screws and nuts securing the top of
the secondary steering post to the chassis. Account
for both steering post blocks and retaining plate.
SNO-2226B
8. Carefully remove the secondary steering post from
the snowmobile.
9. Remove and discard the cotter pin (C) and nyloc nut
(B) securing the steering post to the lower steering
support bracket. Account for a thrust washer (A).
SNO-2225A
10. Remove the two cap screws securing the existing
steering support (C) to the front spar tubes (B); then
remove the two cap screws securing the steering sup-
port to the side support tubes (A). Retain all cap
screws and nuts.
SNO-2227A
11. Remove the two cap screws securing the rear portion
of the steering support to the rear spar tubes.

18
XM212A
12. With the telescoping steering assembly removed
from the snowmobile; press down on the adjusting
block until the inner snap ring is exposed. Remove
the snap ring.
SNO-739A
13. Remove the retaining ring securing the bottom side
of the steering post; then remove the post from the
steering support. Account for two bearings.
SNO-740A
INSPECTING
1. Inspect all welded areas for cracks or deterioration.
2. Inspect the steering post and steering-post retaining
plate for cracks, bends, or wear.
3. Inspect the adjuster caps and mounting block for
cracks or wear.
INSTALLING
1. Insert the telescoping steering post into the steering
support along with two bushings; 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 the steering post and
secure using the existing snap ring.
SNO-739A
3. Install the steering post assembly onto the front and
rear spar tubes and into the thrust washer (A) and the
lower steering post support. Secure with a new nyloc
nut (B) and a new cotter pin (C). Tighten to 20 ft-lb
and spread the cotter pin to secure.
SNO-2225A
4. Secure the steering support to the front and rear spar
tubes using the existing cap screws. Tighten to 25
ft-lb.
5. Install the secondary steering post into position and
secure to the steering stop bracket with a new M10
nut. Be sure to align the steering post ball joint
alignment tab with the steering stop bracket.
Tighten to 43 ft-lb.

19
SNO-2218
6. Secure the tie rod assembly to the steering post using
a new M10 nut. Be sure to align the tie rod ball
joint alignment tab with the steering post. Tighten
to 35 ft-lb.
SNO-2219
7. Secure the right-side steering boot to the chassis
using the existing push rivets.
XM134A
8. Secure the top of the steering post to the steering
support using the existing retaining plate and new
nuts (A). Tighten to 96 in.-lb.
SNO-2226A
9. Connect the tie rod (B) from the adjustable steering
post to the secondary steering post using 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 to the desired position; then
secure using the existing cap and all eight screws.
Tighten evenly to 15 ft-lb.
0747-617
12. Install the upper and lower console; then install the
gas tank and seat using the existing hardware.
13. Install the hood and both access panels.
Steering Post (M)
REMOVING
1. Remove the hairpin clip from the pin located at the
front of the access panel; then unscrew the thumb
screw. Move the panel up and off the pin; then swing
the panel all the way out and unhinge the panel from
the lower console.