Arctic Cat ZR 120 Operator`s manual

ZR® 120
p/n 2259-701
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 Arctic Cat 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
Drive Belt
Torn or Punctured
Wear Bars
Brake Pads
Spark Plugs
Drive Clutch/Driven Pulley 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 service as 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.
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.) 1-218681-9851 or (Canada) 1-204-982-1656.
Table Of Contents
Limited Warranty................................................. Inside Front Cover
Foreword........................................................................................ 1
Specifications ................................................................................ 2
Getting Ready to Operate the ZR 120 Safely ................................ 3
Operating the ZR 120 .................................................................... 4
General Information .................................................................... 5-6
Snowmobile Identification ............................................................ 5
Control Locations......................................................................... 5
Gasoline - Oil ............................................................................... 5
Engine Break-In........................................................................... 6
Muffler.......................................................................................... 6
Operating Instructions ................................................................ 7-8
Starting and Stopping Engine...................................................... 7
Periodic Maintenance/Tune-Up Chart............................................ 9
Maintenance ........................................................................... 10-18
Engine Oil .................................................................................. 10
Carburetor.................................................................................. 11
In-Line Fuel Filter....................................................................... 12
Air Cleaner/Filter........................................................................ 12
Spark Plug ................................................................................. 12
Brake ......................................................................................... 13
Drive Chain ................................................................................ 13
Drive Chain Tensioner ............................................................... 14
Rear Suspension ....................................................................... 14
Track Tension............................................................................. 14
Track Alignment ......................................................................... 15
Adjusting Rear Spring Tension .................................................. 16
Ski Alignment............................................................................. 16
Steering Alignment .................................................................... 17
Ski Wear Bar.............................................................................. 17
Recoil Starter Air Vents ............................................................. 18
Lights ......................................................................................... 18
Preparation for Storage ............................................................... 19
Preparation after Storage ............................................................ 20
Snowmobile Safety Rules............................................................ 21
U.S. EPA Emission Control Statement/Warranty Coverage Snowmobile (U.S. Only)......................................................... 22
Change of Address, Ownership, or Warranty Transfer ................ 23
Warranty Procedure/Owner Responsibility .................................. 25
Declaration Of Conformity ........................................................... 27
Reference 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: _________________________________________
Vehicle Identification Number: _______________________________
Engine Serial Number: _____________________________________
Your Arctic Cat Dealer: ____________________________________
Phone: _________________________________________________
Parts and Accessories
When in need of replacement parts, oil, or accessories for your Arctic Cat snowmobile, be sure to use only 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, a Service Manual and an Illustrated Parts Manual are available through your local Arctic Cat
Snowmobile dealer.
The ZR 120 Snowmobile is intended to be a learning/recreational snowmobile for a
responsible child at least 6 years of age under adult supervision. This snowmobile is
intended to be ridden by the operator only; there should be no passenger. Also, this
snowmobile is intended for daylight use in restricted off-road areas, primarily on
snow. Use of this snowmobile on public streets, roads, and highways can be hazardous and is prohibited by law in most cases. As a parent or guardian, one must accept
the responsibility of training the child in the safe operation of the snowmobile. Teach
all operators the basic principles of operation, snowmobile rules and regulations, and
especially how to stop the snowmobile in case of an emergency. Impress upon the
child a sense of snowmobile courtesy and responsibility.
This snowmobile is a quality Arctic Cat product designed, engineered, and assembled
to give dependable service. Be sure, as the owner, to become thoroughly familiar with
its basic operation, maintenance, and storage procedures. Read this manual and the
accompanying Snowmobile Safety Handbook to ensure safe and proper use of the
This manual is divided into sections. The sections Getting Ready to Operate the ZR
120 Safely and Operating the ZR 120 must be read and explained to the child/operator. The other sections are for the owner/parent/guardian and contain information on
snowmobile identification, safe operating instructions, lubrication, maintenance, storage, and after-storage preparation. If repair or service is ever required, contact an
authorized Arctic Cat Snowmobile dealer for professional service.
The Operator’s Manual, Snowmobile Safety Handbook, and snowmobile decals display 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 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.
At the time of publication, all information and illustrations were technically correct.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive
obligation is incurred.
This Arctic Cat Operator’s Manual should be considered a permanent part of the
snowmobile and must remain with the snowmobile at time of resale. If the snowmobile changes ownership, contact Arctic Cat Inc., Product Service and Warranty
Department, P. O. Box 810, Thief River Falls, MN 56701, for proper registration
information. This manual was prepared by the Product Service and Warranty Department of Arctic Cat Inc.
Every Arctic Cat snowmobile meets or exceeds the standards of the Snowmobile
Safety and Certification Committee 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 laws, and respect the rights of
others. International Snowmobile Manufacturers Association (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 promotes snowmobiling through education, charity, and research programs.
© 2013 Arctic Cat Inc.
Printed in U.S.A.
April 2013
Forced Air Cooled/4-Cycle
Bore x Stroke
56 x 50 mm (2.2 x 1.97 in.)
Valve Arrangement
123 cc (7.5 cu in.)
Lighting Coil Output
Compression Ratio
Forced Splash
Cooling System
Forced Air
Drive Clutch
Drive Chain Tensioner
Brake Type
Ignition Type
Track Width
25.4 cm (10 in.)
Track Length (On Ground)
43 cm (17 in.)
Track Tension (Range)
6.4-9.5 mm (1/4-3/8 in.)
Track Style
Spark Plug Type
Spark Plug Gap
0.7-0.8 mm (0.028-0.031 in.)
Ignition Timing (Fixed)
24° BTDC @ 3600 RPM
Mikuni BV18-11-84Z1
Overall Length
181.6 cm (71.5 in.)
Overall Height
78.7 cm (31 in.)
Overall Width
87.6 cm (34.5 in.)
Ski Center-to-Center Distance (Stance)
78 cm (31 in.)
Gasoline (Recommended)
87 Minimum Octane Regular Unleaded
Gas Tank Capacity (Actual)
1.7 L (0.46 U.S. gal.)
Gas Tank Capacity (Rated)
1.5 L (0.40 U.S. gal.)
Engine Oil (Recommended)
Synthetic 0W-40
Crankcase Oil Capacity
600 ml (20.3 fl oz)
Air Cleaner
Semi-Dry Polyurethane Foam Element
Suspension Grease
Taillight (p/n)
Headlight Bulb (p/n)
Starting System
Manual Recoil
Dry Weight
75.0 kg (165 lb)
Curb Weight (approx)
76.8 kg (169 lb)
Specifications subject to change without
Getting Ready to Operate the
ZR 120 Safely
 NOTE: This section and Operating Second, you must check several things
the ZR 120 section must be read and every time before the engine is started.
explained to the child/operator by
the owner/parent/guardian. Refer to A. Make sure the brake lever works
properly (moves freely) by pulling
Control Locations or the snowmobile
(squeezing) the brake lever and
while explaining this section.
releasing it several times.
Like most boys and girls, you are anxiously waiting to drive the snowmobile. B. Make sure the throttle lever works
properly (moves freely) and that it
Remember that the snowmobile is not a
snaps back to the idle position
toy. It must be driven carefully at all
quickly when it is released. The idle
position is when the throttle lever is
First, you must understand the controls,
farthest away from the handlebar
know where the controls are, and know
grip. If the throttle lever does not
how to use them correctly.
snap back quickly, the engine must
not be started and the throttle system
A. BRAKE LEVER — To slow
must be repaired.
down or stop the snowmobile, the
brake lever should be pulled C. Make sure that you have enough
(squeezed) toward the handlebar
clothes on to keep yourself warm but
NEVER wear clothes such as long
or loose scarves or long shoe laces
 NOTE: When the brake is being
that could get caught in a moving
used, the throttle lever must be in
part of the snowmobile.
the idle (released) position.
Third, make sure that you can answer yes
B. THROTTLE LEVER — Controls to all of the following questions before
the speed of the snowmobile. The each ride.
closer the throttle control lever is to
the handlebar grip (the more it is A. Do you have permission from the
owner or parent or guardian to opersqueezed), the faster the snowmoate the snowmobile?
bile will go.
C. IGNITION SWITCH — When B. Do you have an approved safety helmet on?
the key is in the OFF position, the
engine will neither start nor run. If C. Are you wearing something to prothe key is in the RUN position, the
tect your eyes (such as goggles or a
engine will start and run.
D. EMERGENCY STOP SWITCH D. Are you dressed warmly enough?
— If something happens that you do
E. Has your parent or guardian checked
not understand or if there is an emerto make sure you have enough gasogency, move the emergency stop
switch to the OFF (down) position to
immediately stop the engine.
F. Do the throttle lever and brake lever
move freely?
engine will neither start nor run
G. Are all shields and covers in the
unless the tether switch cap is conright place and is the hood securely
nected to the tether switch located
on the top right-hand side of the console. The tether cord MUST BE H. Do you have a safe area to ride in? Is
the area free of rocks, wires, trees,
clipped to the operator’s right wrist
traffic, etc.?
before attempting to start the engine.
Operating the ZR 120
You must be a responsible, careful, and
considerate snowmobile operator at all
times. Your safety is our concern and
must always be yours.
A. When you are learning how to operate the snowmobile, have a parent or
guardian take you to an open area to
practice figure eights, starting, and
stopping. This practice is important
and will give you a good “feel” of
the snowmobile. You will also be
able to learn how the snowmobile
handles under different conditions
(deep snow, hard-packed snow, etc.).
B. Always sit on the seat and keep both
feet on the running boards when
operating the snowmobile. Do not
get off the snowmobile until it has
come to a complete stop.
C. Never drive the snowmobile faster
than a safe speed. Do not drive too
close to roads, buildings, trees, other
snowmobiles, or people. Never
show off!
D. Never operate the snowmobile
unless the headlight and taillight are
in working order.
E. The snowmobile is designed for
your enjoyment. DO NOT give rides
to your friends. It is made to carry
only one person.
F. Do not pull sleds, sleighs, etc.,
behind the snowmobile.
G. If you get stuck, shut the engine off
and get help.
General Information
Control Locations
This snowmobile has two identification
numbers: The Vehicle Identification
Number (VIN) is stamped into the right
side of the tunnel and the Engine Serial
Number (ESN) is stamped into the front
side of the crankcase.
Gasoline - Oil
This snowmobile has a four-cycle
engine; therefore, it is unnecessary to
premix gasoline and oil.
Recommended Gasoline
The recommended gasoline to use in this
snowmobile is 87 minimum octane regular unleaded. Oxygenated gasolines are
acceptable gasolines. Do not use gasolines containing methanol.
Do not use white gas or gasolines
containing methanol. Only Arctic Cat
approved gasoline additives may be
These numbers are required by the dealer
to complete warranty claims properly. No
warranty will be allowed by Arctic Cat if
either the ESN or VIN is removed or
mutilated in any way.
 NOTE: If not satisfied with gasoline economy of the engine when
using a gas/alcohol blend, switch to
unleaded gasoline without alcohol.
Since gasoline expands as its temperature
increases, the gas tank must be filled to
its rated capacity only. Expansion room
must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area.
Always provide the snowmobile model
name, VIN, and engine serial number
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
Always fill the gas tank in a well-ventiinformation.
lated area. Never add gasoline to the
gas tank near any open flames or with
the engine running. DO NOT SMOKE
while filling the gas tank.
Recommended Oil
 NOTE: This snowmobile comes
from the factory with SAE 0W-40
synthetic oil installed.
The recommended oil to use in the Engine Break-In
engine is 0W-40 Synthetic oil. See the The engine requires a short break-in
viscosity chart for details.
period (approximately 10 operating
hours) before being subjected to heavy
load conditions or full-throttle operation.
Any oil used in place of the recom- Strict adherence to the break-in procemended oil may cause serious engine dure will contribute to optimum perfordamage.
mance and longevity of the engine.
During break-in, a maximum of 1/2
throttle is recommended; however, brief
full-throttle accelerations and variations
in driving speeds contribute to good
engine break-in. After the 10 hour breakin period, the snowmobile may be taken
to an authorized Arctic Cat Snowmobile
dealer for a checkup and oil change. This
service is at the discretion and expense of
the snowmobile owner.
The muffler is designed to reduce engine
noise and improve the total performance
of the engine. If the muffler is removed
from the engine, severe engine damage
will result.
Operating Instructions
Starting and Stopping
Never allow anyone to stand in front of
the snowmobile at any time, especially
when starting the engine.
It is imperative that all safety checks
found in the accompanying Snowmobile
Safety Handbook be performed before
attempting to start the engine.
This snowmobile is equipped with a recoil
starter. The recoil starter handle is located
on the lower right-hand side of the console.
3. Insert the key into the ignition
switch; then rotate the key to the
RUN position.
 NOTE: Make sure the emergency
 NOTE: If the recoil starter rope stop switch is in the ON (up) position
should break or if the recoil starter and the tether cap is connected to
should malfunction, take the snow- the tether switch.
mobile to an authorized Arctic Cat
4. For a cold engine, pull the choke out
Snowmobile dealer for service.
To start the engine, use the following procedure:
completely. If the engine is warm,
choking is not normally necessary.
5. Pull the recoil starter handle slowly
until resistance is felt; then give a
short quick pull. The engine should
start; however, if the engine does not
start, repeat this step.
1. Test the throttle lever by completely
compressing and releasing it several
times. The lever MUST return to the
idle position quickly and completely.
2. Open the gas tank shut-off valve
located under the gas tank by rotating
the valve counterclockwise. Open the
valve completely; otherwise, it may
close during operation of the snowmobile due to engine vibration.
To avoid damaging the recoil starter,
DO NOT pull the recoil starter rope to
its limit or release the recoil starter
handle from an extended position.
Allow recoil rope to rewind slowly.
6. When the engine starts, push the
choke approximately half way in.
Allow a cold engine to “warm up”
for approximately 2-3 minutes. The
choke should be pushed in completely after the “warm up.”
7. Flooding - If the engine does not
start when the choke is being used
but seems ready to start, push the
choke in completely.
 NOTE: Continued choking will only
cause the engine to flood more.
 NOTE: If the engine fails to start
during the attempt with the throttle
lever compressed, remove the spark
plug and clean and dry it thoroughly
or install a new, properly gapped,
recommended spark plug.
8. To shut the engine off, turn the ignition key to the OFF position, move
the emergency stop switch to the
OFF (down) position, or pull the
tether cap from the tether switch.
 NOTE: Unless the engine will be
started within a short period of time,
close the gas tank shut-off valve
(located under the gas tank) by rotating the valve clockwise.
If the snowmobile is not to be used for
an extended period of time, be sure to
close the gas tank shut-off valve.
Periodic Maintenance/Tune-Up Chart
Valve Clearance
Spark Plug
Fuel Supply Hose
Gas Tank Shut-Off
Carburetor Float
Engine Oil
Cap Screws
Rear Suspension
Recoil Starter
Air Filter
Pilot Air Screw
In-Line Fuel Filter
C = Clean
I = Inspect
R = Replace
T = Tighten
1st 10
Every 20 Every 50 Every 100 Every 300
(2 Weeks) (1 Month) (3 Months) (6 Months) (12 Months)
Replace every
3 years
IA = Inspect and adjust (if necessary)
IC = Inspect and clean (replace if necessary)
IL = Inspect and lubricate (replace if necessary)
* = Service more frequently if used in adverse conditions
Engine Oil
 NOTE: If the oil level is below the
 NOTE: After the engine break-in oil level mark, add recommended oil
period, the engine oil should be until it reaches the oil level mark.
changed every 100 operating hours (6
4. Insert the oil level stick into the
months) and before prolonged storage.
crankcase; then rotate the stick
clockwise until snug.
5. Close the hood and secure with the
The engine oil level should be checked
each day before operating the snowmobile. To check the engine oil level, use Changing
the following procedure:
To change the engine oil, use the follow NOTE: The front of the snowmo- ing procedure:
bile must be elevated until the bottom of the front bumper is
approximately 47 cm (18.5 in.) off the
floor when checking the oil level.
Also, assure the engine is “cooled
down” to room temperature to allow
the oil to drain into the sump.
 NOTE: The front of the snowmobile must be elevated until the
engine is in a level position when
changing the oil.
1. Remove the access plug; then place
a drain pan beneath the engine.
1. Release the two hold-down straps
and open the hood.
2. Release the two hold-down straps
and open the hood.
2. Rotate the oil level stick counterclockwise; then remove the stick
from the crankcase and wipe it clean.
3. Loosen the oil level stick; then
remove the oil drain plug from the
crankcase and allow the oil to drain.
4. Install the drain plug.
Clean the area around the fill hole to
keep dirt, debris, etc., out of the
5. Remove the oil level stick; then pour
600 ml (20.3 fl oz) of recommended
oil into the fill hole.
3. Insert the stick into the crankcase
and remove and check oil level on
the stick.
6. Install the oil level stick; then
tighten until snug. Install the access
Seeing oil in the crankcase does not
mean the level is in the safe operating range. Always use the oil level
stick to check engine oil. Never operate the engine with the oil level below
the point of overflowing the fill hole.
7. Close the hood and secure with the
The carburetor has been calibrated for
average riding conditions; however, altitude, temperature, and general wear may
necessitate certain carburetor adjustments. Since carburetor adjustments critically affect engine performance, Arctic
Cat recommends that any changes in
internal carburetor calibration be made
by an authorized Arctic Cat Snowmobile
dealer; however, three external adjustments can be made on the carburetor.
These are the throttle stop screw, idle fuel
adjuster screw, and throttle cable.
To adjust the throttle cable, use the following procedure:
Do not attempt to adjust the throttle
cable with the engine running. Personal injury could result.
1. Loosen the throttle cable jam nuts.
2. Pull all slack from the throttle cable
wire and exert slight tension on the
3. Tighten the throttle cable jam nuts.
Throttle Stop Screw
This screw controls the seating position of
the throttle valve which in turn determines
the proper idle speed. Rotate the screw clockwise to increase engine idle speed and counterclockwise to decrease engine idle speed.
Idle Fuel Adjuster Screw
This adjuster screw determines the fuel/
air mixture for idling. To adjust, use the
following procedure:
DO NOT operate the snowmobile
when any component in the throttle
system is damaged, frayed, kinked,
worn, or improperly adjusted. If the
snowmobile is operated when the
throttle system is not functioning
properly, personal injury could result.
Speed Control Screw
1. Start the engine and allow to run at
half throttle 5-10 minutes to warm up.
2. Place the throttle in the idle position;
then rotate the idle fuel adjuster
screw/cap in or out within the
adjustment range to obtain smooth
low speed performance.
Throttle Cable
The maximum speed of the snowmobile
can be reduced by adjusting the speed
The correct throttle cable adjustment is control screw.
when (with the engine OFF) the carburetor throttle is completely open (against its To reduce the maximum speed, rotate the
limit) while the throttle lever comes just speed control screw clockwise. DO NOT
short of contacting the handlebar grip. EVER INCREASE THE MAXIMUM
With the lever in this position, the throttle SPEED BEYOND THE ORIGINAL 8
arm on the carburetor should be in con- MPH MAXIMUM!
tact with the speed control screw.
In-Line Fuel Filter
Whenever any maintenance or inspection is made on a fuel system when
there may be fuel leakage, there
should be no welding, smoking, open
flames, etc., in the area.
Arctic Cat recommends that the in-line
fuel filter be checked once a month. The
filter is located in the fuel hose between the
gas tank and carburetor. The only cleaning
possible is to back-flush the filter using
clean gasoline. To check, clean, or replace
the filter, use the following procedure:
Failure to inspect the air filter frequently if the snowmobile is used in
adverse conditions can damage the
1. Remove the two screws securing the
air cleaner cover; then remove the
2. Remove the foam filter from the
3. Clean the foam filter in a non-flammable cleaning solvent; then allow
the filter to dry.
1. Turn the gas tank shut-off valve to
the CLOSED position.
 NOTE: Foam Filter Cleaner (p/n
0436-892) and Foam Filter Oil (p/n
2. Remove and discard the clamps; 0436-891) are available from Arctic Cat.
then pry the fuel hoses off the in-line
fuel filter and remove the filter.
4. Put the dry filter in a plastic bag;
then pour in recommended air filter
3. Install the in-line fuel filter in the
oil and work the oil into the filter.
fuel hose so the arrow on the filter
points toward the carburetor. Make
sure the fuel hoses fit tightly on the
filter. If a fuel hose does not fit A torn air filter can cause damage to
tightly, cut 6 mm (1/4 in.) from the the engine. Contaminants may get
end of the fuel hose; then install on inside the engine if the filter is torn.
Carefully examine the filter for tears
the filter. Install new clamps.
The fuel hoses must fit tightly on the
fuel filter. If the fuel hose length
doesn’t permit this procedure, replace
the fuel hose. Also, after installing the
fuel hoses on the filter, check to be
sure that the fuel hoses do not contact any hot or rotating components.
before and after cleaning it. Replace
the filter with a new one if it is torn.
5. Clean any debris from inside the air
cleaner. Be sure no debris enters the
6. Place the filter into the housing.
7. Place the air cleaner cover onto the
housing; then secure with the two
4. Turn the gas tank shut-off valve to
the OPEN position.
Spark Plug
This snowmobile comes equipped with a
Air Cleaner/Filter
The air filter inside the air cleaner housing specified spark plug. See the specifications
must be kept clean to provide good engine chart for the correct spark plug. A light
power and gas mileage. If the snowmobile brown insulator indicates that the plug is
is used under normal conditions, service correct. A white or dark insulator indicates
the filter at the intervals specified. If oper- that the engine may need to be serviced or
ated in adverse conditions, inspect and ser- the carburetor may need to be adjusted.
vice the filter more frequently. Use the Consult an authorized Arctic Cat Snowmofollowing procedure to remove the filter bile dealer if the plug insulator is not a
light brown color. To help prevent cold
and to inspect and/or clean it.
weather fouling, make sure to thoroughly
warm up the engine before operating.
To maintain a hot, strong spark, keep the
plug free of carbon.
Before removing the spark plug, be sure
to clean the area around the spark plug. If
you do not, dirt could enter engine when
removing or installing the spark plug.
Adjust the gap to specified amount (see
specifications chart) for proper ignition.
Use a feeler gauge to check the gap.
3. If travel distance is not as specified,
adjust the brake.
Adjusting Brake Lever
To adjust the brake lever travel, use the
following procedure:
When installing the spark plug, be sure to
tighten it securely. A new spark plug should
be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug
should be tightened 1/8 - 1/4 turn once the
washer contacts the cylinder head.
1. Remove the drive chain shield.
2. Loosen the rearward brake cable jam
nut; then tighten the forward jam nut
to set up the brake.
DO NOT operate the snowmobile
when any component in the brake
system is damaged, worn, or adjusted
Arctic Cat recommends that the complete
brake system be checked daily for wear or
damage and for smooth operation. Periodically, the brake band should be inspected
for cracks and to ensure the liner is intact
and not worn excessively. Replace the
brake band if cracked or worn excessively.
Checking Brake Lever
3. Check the brake lever travel distance
periodically while tightening the forward jam nut. When the distance is
within the specified range of 6-13 mm
(1/4-1/2 in.), tighten the rearward jam
nut to secure the adjustment.
Drive Chain
The drive chain should be lubricated
every 10 operating hours with Arctic Cat
2. Check the distance between the Synthetic Chain Lube (p/n 5639-038) or
brake lever and the lever stop. The with a suitable dry, graphite-based chain
distance must be within the specified lubricant. By using the recommended
range of 6-13 mm (1/4-1/2 in.).
chain lube or a dry, graphite-based chain
lubricant, dirt buildup on the drive chain
will be minimized. Before each lubrication, inspect the drive chain for dirt accumulation.
1. Compress the brake lever fully.
To lubricate the drive chain, shut the
engine off and wait for all moving parts
to stop, remove the drive chain shield,
and lubricate the drive chain. After lubricating the drive chain, install the drive
chain shield.
 NOTE: If the recommended chain
lube or a dry, graphite-based chain
lubricant is not available, lubricate
the drive chain with several drops of
petroleum-based oil. If the snowmobile is operated in the summer with
the optional wheel kit, the drive chain
should be lubricated more frequently.
Drive Chain Tensioner
The drive chain tensioner is automatic;
therefore, no adjustment is required by
the snowmobile owner. The tensioner
and chain should be checked annually for
proper operation and excessive wear and
replaced when necessary. Check the tensioner by pushing down on it and releasing it. It should immediately spring back
and put tension on the drive chain.
Rear Suspension
This procedure should be done every 20
operating hours.
1. Shut engine off and wait for all moving parts to stop.
2. With the gas tank nearly empty (less
than 1/4 full), lay the snowmobile on
its side. A piece of cardboard should
be used to protect the finish on the
hood and belly pan.
3. Remove ice and snow buildup from
the skid frame to expose the two
grease fittings.
Track tension is directly related to the overall performance of the snowmobile. If the
track is too loose, it may slap against the
tunnel causing wear, or it may ratchet on the
track drive sprockets. Arctic Cat recommends that the track tension be checked
once a month and adjusted accordingly.
Track tension must be properly maintained. Personal injury could result if
a track is allowed to become excessively loose.
Checking Track Tension
DO NOT attempt to check or adjust
track tension with engine running.
Turn ignition key to the OFF position.
Personal injury could result from contact with a rotating track.
1. Remove excess ice and snow
buildup from the track, track drive
sprockets, and the inside of the skid
2. Place the rear of the snowmobile up
on a safety stand high enough so the
track is free of the floor.
3. Without exerting any pressure on the
track, measure the distance between
the bottom of the wear strip and the
inside surface of the track. The measurement must be within specifications of 6.4-9.5 mm (1/4-3/8 in.). If
the measurement is not within specifications, an adjustment is necessary.
4. Lubricate the grease fittings with an
all-temperature grease.
Track Tension
 NOTE: Track tension and track
alignment are interrelated; therefore, always check both, even if only
one adjustment seems necessary.
Adjusting Track Tension
1. Loosen the idler wheel cap screws.
2. Loosen the rear idler wheel adjusting bolt jam nuts.
Track Alignment
Proper track alignment is obtained when
the rear idler wheels are equal distance
from the inner track drive lugs. Excessive
wear to the idler wheels, drive lugs, and
track will occur if the track is improperly
aligned. Arctic Cat recommends that the
track alignment be checked once a week
or whenever the track tension is adjusted.
 NOTE: To ensure proper track tension adjustment, perform all adjustments on both sides of the
3. If the deflection (distance between
the bottom of the wear strip and the
inside of the track) exceeds specifications, tighten the adjusting bolts to
take up excessive slack in the track.
4. If the distance between the bottom
of the wear strip and the inside surface of the track is less than specified, loosen the adjusting bolts to
increase the slack in the track.
5. Check track alignment (see Track
Alignment section).
6. When proper track tension is
obtained, tighten the adjusting bolt
jam nuts against the axle housings.
7. Tighten idler wheel cap screws securely.
 NOTE: Since track tension and
track alignment are interrelated,
always check both even if only one
adjustment seems necessary.
Checking Track Alignment
Make sure the ignition key is in the
OFF position and the track is not
rotating before checking or adjusting
track alignment. Personal injury could
result if contact is made with a rotating track.
1. Remove excess ice and snow buildup
from the track, track drive sprockets,
and the inside of the skid frame.
2. Position the tips of the skis against a
wall; then using a shielded safety
stand, raise the rear of the snowmobile off the floor making sure the
track is free to rotate.
The tips of the skis must be positioned against a wall or similar object
for safety.
3. Start the engine and accelerate
slightly. Use only enough throttle to
turn the track several revolutions.
 NOTE: Allow the track to coast to a
stop. DO NOT apply the brake
because it could produce an inaccuIf jam nuts are not tightened properly, rate alignment condition.
the adjusting bolts could loosen causing the track to become extremely
4. When the track stops rotating, check
loose and, under some operating conthe relationship of the rear idler
ditions, allow the idler wheels to climb
wheels and the inner track drive
over the track lugs forcing the track
lugs. If the distance from the rear
against the tunnel causing the track to
idler wheels to the inner track drive
“lock.” If a track “locks” during operalugs is the same on both sides, no
tion, severe personal injury could
adjustment is necessary.
5. After the field test, check the alignment of the track. If additional adjustment is necessary, repeat Adjusting
Track Alignment procedure.
Adjusting Rear Spring
Rear spring tension adjustment is accomplished by rotating the adjusting cams.
Position 3 provides the stiffest ride, and
position 1 is for the light driver or slow5. If the distances from the rear idler speed trail riding. Position 2 is for the
wheels to the inner track drive lugs average operator under normal condiare not the same on both sides, an tions. Always rotate the cam from the
lighter position to the heavier position.
adjustment is necessary.
Adjusting Track Alignment
1. On the side of the track which has Never force the adjustment cams from
the inner track drive lugs closer to the low position to the high position.
the rear idler wheel, loosen the idler Cam damage may occur.
wheel cap screw and the adjusting
bolt jam nut; then rotate the adjusting bolt clockwise 1 to 1 1/2 turns.
Using a 13/16 in. wrench, rotate the cam
until it is in the desired position. To
stiffen the ride, rotate the cam so as to
2. Check track alignment and continue raise the spring end. Make the adjustment
adjustment until proper alignment is on the other cam and be sure both cams
are adjusted equally.
 NOTE: Make sure correct track Ski Alignment
tension is maintained after adjust- The skis have been aligned during setup of
ing track alignment (see Track Ten- the snowmobile. Ski alignment usually will
sion section).
not change unless a rock or similar hard
3. After proper track alignment is object is hit while the snowmobile is being
obtained, tighten both the adjusting operated. Arctic Cat recommends that the
bolt jam nut and the idler wheel cap ski alignment be checked once a week.
screw securely.
Checking Ski Alignment
1. Turn the handlebar to the straight! WARNING
ahead position.
If a jam nut is not tightened properly,
the adjusting bolt could loosen caus2. Measure the distances to the inside
ing the track to become dangerously
edges of the skis. Make sure the
measurements are taken behind the
front mount bracket and ahead of the
4. Field test the track under actual conrear mount bracket.
Steering Alignment
Visually examine the steering alignment
by placing the handlebar in the straightahead position and checking to be sure
the skis are pointing straight ahead. If the
skis are not pointing straight ahead,
adjust using the following procedure:
 NOTE: The following procedure
 NOTE: Ski alignment is correct
when the skis are parallel to each
other (equal measurements front
and rear) or when the skis have up to
a maximum of 6 mm (1/4 in.) “toe
out” (front measurement 6 mm (1/4
in.) more than rear measurement).
can be used to adjust the alignment
of either ski.
1. Determine which ski is out of alignment; then unlock the adjustment tie
rod by loosening the jam nuts.
3. If ski alignment is not as specified,
the snowmobile will have a tendency to wander and may be difficult to control; therefore, an
adjustment is necessary.
Adjusting Ski Alignment
1. Make sure the ignition key is in the
OFF position.
2. Adjust the ski alignment by rotating
the adjustment tie rod.
2. Visually examine the skis to determine which ski is out of alignment
with respect to the handlebar.
3. When steering alignment is correct,
apply blue Loctite #243 to the jam
nut threaded areas and tighten each
jam nut securely against its adjustment tie rod.
3. Open the hood and loosen the jam nut
on each end of the adjustment tie rod.
4. While holding the ski in position,
rotate the adjustment tie rod until the
measurement between the skis is Neglecting to lock the steering tie rod
by tightening the jam nuts against the
within specifications.
5. When the ski alignment is correct,
apply blue Loctite #243 to the jam
nut threaded areas and tighten each
jam nut securely against its adjustment tie rod.
Neglecting to lock the tie rod by tightening the jam nuts against the adjustment tie rod may cause loss of
snowmobile control and possible personal injury.
adjustment tie rod may cause loss of
snowmobile control and possible personal injury.
Ski Wear Bar
The ski wear bar is a replaceable bar
attached to the underside of the ski. The
purpose of the wear bar is to assist in
turning the snowmobile, to minimize ski
wear, and to maintain good steering control. If the snowmobile is operated primarily in deep snow, ski wear bar wear
will be minimal; however, if the snowmobile is operated on terrain where the
snow cover is minimal, the ski wear bar
will wear faster.
To maintain positive steering characteristics, Arctic Cat recommends that the ski
wear bars be checked once a week and
replaced if worn to 1/2 of original diame- Serious overheating of the engine
ter. Ski wear bars are available from an and engine damage will result if the
authorized Arctic Cat Snowmobile dealer. air vents are not kept clean.
Operating the snowmobile with
excessively worn ski wear bars may
result in a loss of steering control.
Removing Ski Wear Bar
1. Raise the front of the snowmobile.
2. Remove the lock nuts securing the
wear bar to the ski.
The correct headlight bulb is p/n 0609251. The correct taillight is p/n 0609-934.
To change the headlight bulb, use the following procedure:
1. Open the hood; then disconnect the
harness connector from the headlight bulb.
2. Remove the bulb from the housing
by rotating it counterclockwise until
Do not touch the glass portion of the
bulb. If the glass portion is touched, it
must be cleaned with a dry cloth
before installing.
3. Remove the wear bar.
3. Install the new bulb into the housing; then rotate the bulb clockwise to
lock it into place.
The headlight aim can be adjusted to provide maximum illumination for the oper1. Insert the wear bar studs into the ator. To adjust headlight aim, adjust the
four headlight adjustment screws until
holes in the ski.
maximum illumination for the operator is
2. Center the wear bar studs in the apparent.
holes and install the lock nuts.
Installing Ski Wear Bar
3. Tighten lock nuts securely.
Recoil Starter Air Vents
It is important for proper engine cooling
that the air vents located on the recoil
starter are kept clean. These air vents
should be checked periodically and
cleaned if necessary.
Preparation for Storage
Prior to storing the snowmobile, it is
extremely important that it be properly
serviced to prevent corrosion and component deterioration. Arctic Cat recommends the following procedure to
prepare the snowmobile for storage.
1. Clean the seat cushion with Vinyl
Protectant and a damp cloth.
2. Clean the snowmobile thoroughly
by hosing dirt, oil, grass, and other
foreign matter from the undercarriage, tunnel, hood, and belly pan.
Allow the snowmobile to dry thoroughly. DO NOT get water into any
part of the engine.
3. Drain all gas from the gas tank.
Close the gas tank shut-off valve by
rotating it clockwise; then drain the
gasoline from the carburetor by
loosening the drain screw on the carburetor float chamber.
4. Plug the muffler outlet with a clean
C. Install the spark plug and connect the high tension wire.
6. Remove the drive chain and clean
thoroughly in a solvent. Install drive
chain and lubricate with a dry,
graphite-based chain lubricant.
7. Change the oil; then clean the air filter.
8. Lubricate the spindles and the rear
suspension with an all-temperature
9. Tighten all screws, nuts, and cap
screws securely.
10. Make sure all rivets holding components together are tight. Replace all
loose rivets.
11. Clean and polish the hood, console,
and chassis with Cat Cleaner (p/n
A. Disconnect the high tension wire
from the spark plug; then remove
the spark plug.
12. If possible, store the snowmobile
indoors. Raise the rear of the snowmobile off the floor and block up the
rear end. Cover the snowmobile
with a snowmobile cover to protect
it from dirt and dust.
B. Pour 10 ml (approximately two
teaspoons) of petroleum-based
oil into the spark plug hole; then
pull the recoil starter handle
slowly about five times.
13. If the snowmobile must be stored
outdoors, block the entire snowmobile off the ground and cover it with
a snowmobile cover to protect it
from dirt, dust, and rain.
5. With the ignition key in the OFF
Never crank the engine over without Avoid using a plastic cover as
grounding the spark plug. Damage to moisture will collect on the snowthe transistorized ignition may result. mobile causing corrosion.
Preparation after Storage
Taking the snowmobile out of storage
and correctly preparing it for operation
will assure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure to
prepare the snowmobile.
1. Clean the snowmobile thoroughly.
Polish the exterior of the snowmobile using the cleaner.
2. Clean the engine cooling fins and
the recoil starter vents. Remove the
cloth from the muffler.
3. Check 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 rotating parts.
4. Inspect the drive chain and drive
chain tightener. Replace if necessary.
5. Lubricate the drive chain with recommended lube or with a dry,
graphite-based chain lubricant.
6. If not done during preparation for
storage, lubricate the spindles and
the rear suspension with an all-temperature grease.
7. Check brake-lever travel distance,
all controls, ski alignment, track tension, track alignment, brake band,
and ski wear bars; adjust or replace
as necessary.
8. Examine the in-line fuel filter and
clean or replace if necessary.
9. Fill the gas tank.
10. Clean the seat cushion with the vinyl
11. Check the spark plug (clean, gap,
and/or replace as necessary); then
start the engine and ensure proper
carburetor adjustments.
Snowmobile Safety Rules
U.S. EPA Emission Control Statement/Warranty
Coverage - Snowmobile (U.S. Only)
Arctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPAcertified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA Emission
Control Regulations. Please read the following information completely.
Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-related
component at no cost to you during the warranty period. You may have non-warranty service performed
by any repair establishment that uses equivalent components. The regulations provide significant civil
penalties for tampering that causes your snowmobile to no longer meet U.S. EPA emission standards.
Arctic Cat further warrants that the engine and its emission-related components are free from defects
in materials or workmanship that could cause the engine to fail to comply with applicable regulations
during the warranty period.
If you have any questions about this information, or the emission warranty coverage statement, contact
your local authorized Arctic Cat snowmobile dealer.
The emission warranty period for this snowmobile begins on the same date as the standard warranty
coverage and continues for 30 months or 2500 miles, whichever comes first.
The emissions warranty covers major emissions control components and emission-related
components listed as follows:
Engine Management and Sensors
Barometric Pressure Sensor
Camshaft Position Sensor
Engine Control Unit (ECU)
Engine Coolant Temperature Sensor
Intake Air Temperature Sensor
Manifold Absolute Pressure Sensor
Oxygen Sensor
Throttle Position Sensor
Fuel/Air System
Fuel Injectors
Fuel Pressure Regulator
Fuel Pump
Turbocharger Assembly
Air Bypass Valve
Turbo Waste Gate Control Valve
Crankcase Ventilation System
ISC Valve
Ignition System
Miscellaneous Items Used in Aforementioned
Ignition Coil
Knock Sensor System
Crankshaft Position Sensor
Exhaust Temperature Sensor
Capacitive Discharge Ignition (CDI) Module
Magneto Pick-Up
The owner of any snowmobile warranted under this Arctic Cat Emission Control Statement is
responsible for the proper maintenance and use of the snowmobile as stated in the Operator's Manual.
Proper maintenance generally includes replacement and service, at the owner's choosing, such items
as air filter, oil and oil filter, or any other part, item, or device related to emissions control as specified in
the Operator's Manual. It is the owner's responsibility to ensure that the snowmobile is used in a
manner for which it was designed.
Change of Address, Ownership, or Warranty
Arctic Cat Inc. keeps on file the current name and address of the
owner of this vehicle. This allows Arctic Cat to reach the current
owner with any important safety information which may be
necessary to protect customers from personal injury or property
damage. Please make sure a copy of this form is completed and
returned to Arctic Cat Inc. if you move or if the vehicle is sold to
another party.
This form may also be used to transfer the unused portion of the
original warranty to a second party. In order to transfer warranty,
fill out this form completely; then return a copy of this form to
Arctic Cat Inc. Arctic Cat will then process the application and
issue warranty for the balance of the time remaining of the
original warranty. 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.
Address Change
Ownership Change
Warranty Transfer
Name ________________________________________
Address ______________________________________
City/State (Province)/Zip Code (Postal Code) __________
Phone # (
) __________________________________
Year and Model _________________________________
Vehicle Identification Number (VIN) _________________
Fold Back
P.O. BOX 810
Warranty Procedure/Owner Responsibility
At the time of sale, an Owner Registration form is to be completed by the selling
dealer and consumer. The receipt of the registration form by Arctic Cat is a condition precedent to warranty coverage. It is the selling dealer’s responsibility to retain
and/or submit the appropriate copies of the form to the appropriate place(s) to initiate warranty coverage.
The dealer will furnish to the consumer a signed copy of the form which must be
presented to the dealer when requesting warranty service. The registration form is
the consumer’s proof of ownership and warranty eligibility. The form is used
by the dealer to validate the warranty claim. Retain your copy of the form and
keep it in a safe place.
When warranty repair is suspected, the snowmobile should be taken to the selling
dealer, who has the primary responsibility to perform warranty repairs. Subject to
the limitations set forth in the Limited Warranty, in the event the selling dealer has
ceased to do business, you have moved, or you are in a location away from your
selling dealer, warranty may be performed by any authorized Arctic Cat Snowmobile dealer.
The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or part
to determine if, in his opinion, a warrantable condition exists. If a warrantable condition appears to exist, the dealer will repair or replace, at Arctic Cat’s option, free
of charge, including any related labor costs, all parts that are found to be warrantable and any other parts which the warrantable part caused to be damaged. You, the
consumer, will then be asked to sign a warranty form to ensure Arctic Cat that the
warranty work was actually performed.
It is the consumer’s responsibility to maintain and service the snowmobile in accordance with Arctic Cat’s recommendations in the Operator’s Manual. To protect
yourself and your snowmobile, follow all safety and service tips. Arctic Cat will
NOT warrant repairs required as a result of not performing standard operator
maintenance, storage procedures, and service as outlined in the Operator’s
Should you have any questions concerning the warranty, contact an authorized Arctic Cat Snowmobile dealer.
Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558
Declaration Of Conformity
Application of council directives:
EMC Directive 2004/108/EEC
EC Machinery Directive 2006/42/EEC
Issued by European Commission.
Type of Equipment: Snowmobile
Brand Name: Arctic Cat
Model Numbers:
Standards to which conformity is declared:
EN 55012, EN 61000-6-2
Manufacturer (if not issuing agent): Arctic Cat Inc.
601 Brooks Ave. S.
Thief River Falls, MN
56701 USA
I, the undersigned, hereby declare that the equipment specified above conforms to the
directive(s) and standard(s) as specified.
Brad Darling
Vice President/General Manager - Snowmobile Division