Arctic Cat ZR 120 Service manual

ZR 120
2014
SERVICE MANUAL
[SNOWMOBILE]
FOREWORD
This Arctic Cat Service Manual contains service and maintenance information for the 2014 Arctic Cat ZR 120 Snowmobile. 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.
This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures
found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special
tools to be completed. The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools.
All Arctic Cat publications 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, photographs, and illustrations were technically correct. Some photographs
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.
Keep this manual accessible in the shop area for reference.
Product Service and Warranty Department
Arctic Cat Inc.
© 2013 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN
Effective May 2013
TABLE OF CONTENTS
General Information ................................................... 2
Snowmobile Identification................................... 2
Recommended Gasoline and Oil ....................... 2
Break-In Procedure ............................................ 2
Genuine Parts .................................................... 3
Drive Chain Lubrication ...................................... 3
Preparation For Storage ..................................... 3
Preparation After Storage................................... 3
Torque Conversions (ft-lb/N-m) .......................... 4
Torque Specifications ......................................... 4
Engine Torque Diagram...................................... 5
Engine Specifications ......................................... 6
Carburetor Specifications ................................... 6
Track Specifications............................................ 6
Ski Shock Spring Specifications......................... 6
Rear Arm Spring Specifications ......................... 6
Ski Shock Absorber Specifications..................... 6
Idler Wheel Dimensions ..................................... 6
Engine ........................................................................ 7
Removing ........................................................... 7
Disassembling .................................................... 8
Servicing Components ..................................... 12
Assembling....................................................... 18
Installing ........................................................... 23
Changing Oil..................................................... 24
Recoil Starter ................................................... 24
Troubleshooting Engine.................................... 26
Fuel System ............................................................. 27
Pre-Maintenance Checks ................................. 27
Carburetor ........................................................ 27
Throttle Cable................................................... 30
Troubleshooting Fuel System ........................... 32
Electrical System...................................................... 33
Transistorized Ignition System.......................... 33
Testing Ignition Switches .................................. 34
Testing Electrical Resistances .......................... 34
Drive Chain and Sprockets....................................... 35
Track and Driveshaft................................................. 36
Brake System ........................................................... 40
Troubleshooting Track............................................... 42
Rear Suspension...................................................... 43
Removing Skid Frame ...................................... 43
End Cap............................................................ 44
Wear Strip......................................................... 44
Rear Suspension Arm/Rear Springs ................ 45
Rear Idler Wheels and Axle .............................. 45
Upper Idler Wheels ........................................... 46
Slide Rail .......................................................... 46
Installing Skid Frame ........................................ 48
Steering and Body.................................................... 49
Steering Post .................................................... 49
Ski .................................................................... 52
Ski Wear Bar..................................................... 52
Tie Rods .......................................................... 52
Spindle ............................................................. 53
Ski Alignment.................................................... 54
Front Suspension A-Arms ............................... 55
Front Suspension (Ski) Shock Absorber........... 55
Belly Pan .......................................................... 56
Seat/Cushion/Taillight Housing ........................ 57
Headlight Assembly ......................................... 58
Wiring Diagram......................................................... 59
1
General Information
These numbers are required to complete warranty claims
properly. No warranty will be allowed by Arctic Cat Inc.
if the engine serial number or VIN is removed or mutilated in any way.
NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.
NOTE: Some illustrations and photographs used in
this manual are used for clarity purposes only and are
not designed to depict actual conditions.
SPECIAL TOOLS
A number of special tools must be available to the technician when servicing this snowmobile.
Description
p/n
V Blocks
0644-535
Surface Plate
0644-016
Ball Hone
0644-290
Shock Spring Removal Tool
0644-057
Fluke Model 77 Multimeter
0644-559
Recommended Gasoline
and Oil
RECOMMENDED GASOLINE
CAUTION
Do not use white gas or gasolines containing methanol. Only Arctic Cat approved gasoline additives
should be used.
The recommended gasoline to use in these snowmobiles
is 87 octane regular unleaded.
NOTE: In many areas, oxygenates are added to the
NOTE: Special tools are available from the Arctic Cat
Service Parts Department.
Snowmobile
Identification
The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number (VIN)
is stamped into the tunnel near the right-side footrest.
The Engine Serial Number (ESN) is stamped into the
crankcase of the engine.
gasoline. Oxygenated gasolines containing up to 10%
ethanol are acceptable gasolines; however, whenever
using oxygenated gasolines, the carburetor main jet
must be one size larger than the main jet required for
regular unleaded gasoline. For example, if a 77.5 main
jet is recommended for regular unleaded gasoline, a
78.5 main jet must be installed if using an oxygenated
gasoline.
When using ethanol blended gasoline, adding a gasoline
antifreeze is not necessary since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED OIL
The recommended oil to use in the engine is 0W-40 Synthetic oil. See the viscosity chart for details.
CAUTION
Any oil used in place of the recommended oil may
cause serious engine damage.
0726-200
OILCHARTJ
Break-In Procedure
0744-926
2
The Arctic Cat engine requires a short break-in period
(approximately 10 operating hours) before being subjected to heavy load conditions or full-throttle operation.
Strict adherence to the break-in procedure will contribute
to optimum performance 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 break-in period, the snowmobile may be taken to an authorized Arctic Cat Snowmobile dealer for a checkup and oil change at the discretion
and expense of the snowmobile owner.
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.
Drive Chain Lubrication
The drive chain should be lubricated every 20 operating
hours with a dry, graphite-based chain lubricant. By
using 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.
To lubricate the drive chain, shut the engine off and wait
for all moving parts to stop, remove the drive chain
guard, and lubricate the drive chain. After lubricating the
drive chain, install the drive chain guard.
If the drive chain is excessively dirty, it should be
removed and cleaned prior to being lubricated (see Drive
Chain and Sprockets section).
NOTE: If 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.
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 cloth.
A. Disconnect the high tension wire from the spark
plug; then remove the spark plug.
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.
CAUTION
Never crank the engine over without grounding the
spark plug. Damage to the transistorized ignition may
result.
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 grease.
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 4639-371). DO NOT USE SOLVENTS. THE PROPELLANT WILL DAMAGE
THE FINISH.
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.
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.
CAUTION
Avoid using a plastic cover as moisture will collect on
the snowmobile 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.
5. With the ignition key in the OFF position:
3
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.
Torque Specifications
4. Inspect the drive chain and drive chain tightener.
Replace if necessary.
5. Lubricate the drive chain with a dry, graphitebased 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 protectant.
11. Check the spark plug (clean, gap, and/or replace as
necessary); then start the engine and ensure proper
carburetor adjustments.
Torque Conversions
(ft-lb/N-m)
ft-lb
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
4
N-m
1.4
2.7
4.1
5.4
6.8
8.2
9.5
10.9
12.2
13.6
15
16.3
17.7
19
20.4
21.8
23.1
24.5
25.8
27.2
28.6
29.9
31.3
32.6
34
ft-lb
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
N-m
35.4
36.7
38.1
39.4
40.8
42.2
43.5
44.9
46.2
47.6
49
50.3
51.7
53
54.4
55.8
57.1
58.5
59.8
61.2
62.6
63.9
65.3
66.6
68
ft-lb
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
N-m
69.4
70.7
72.1
73.4
74.8
76.2
77.5
78.9
80.2
81.6
83
84.3
85.7
87
88.4
89.8
91.1
92.5
93.8
95.2
96.6
97.9
99.3
100.6
102
ft-lb
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
N-m
103.4
104.7
106.1
107.4
108.8
110.2
111.5
112.9
114.2
115.6
117
118.3
119.7
121
122.4
123.8
125.1
126.5
127.8
129.2
130.6
131.9
133.3
134.6
136
Item
Torque
ft-lb
Drive System
Centrifugal Clutch
20
Secondary Sprocket***
20
Drive Sprocket Bearing/Chassis*
15
Rear Suspension
End Cap/Rail
78 in.-lb
Axle Housing/Rail
20
Rear Arm/Bracket*
20
Rear Idler Wheel/Axle*
20
Cross-Brace Axle/Rail*
20
Idler Axle/Tunnel*
20
Steering/Body
Outer Tie Rod End/Spindle**
15
Inner Tie Rod End/Steering Post**
20
Ski Shock/Shock Mount
20
A-Arm/Spindle
30
A-Arm/Chassis
30
Ski/Spindle
16
*w/Blue Loctite #243
** w/Green Loctite #609
*** w/Red Loctite #271
Engine Torque Diagram
NOTE: Before engine assembly, ensure all threaded areas are clean to assure an accurate torque value is
achieved. Torque values have a range of ± 20%.
= Torque control required
= Apply Loctite
= Lubricate with Arctic Cat 4-Stroke Engine Oil
= Lubricate with Arctic Cat All-Temp Grease
120-ENG10
5
Engine Specifications
Engine Model Number
70CL1-030
Displacement
123 cc
No. of Cylinders
1
Bore x Stroke
56 x 50 mm
Cooling System
Air
Spark Plug (NGK)
BPR4ES
Spark Plug Gap
0.028-0.031"
Piston Skirt/Cylinder Clearance
0.0006-0.0016"
Piston Pin Diameter
0.6297-0.6299"
Piston Pin Bore Diameter (max)
0.433"
Piston Pin/Connecting Rod Small End Clearance
0.0001-0.0002"
Piston Ring End Gap
Carburetor
Specifications
Main Jet
Pilot Jet
77.5
37.5
Track Specifications
Length
68"
(1st/2nd) 0.008-0.016"
(oil) 0.0079-0.0157"
Piston Ring/Groove Clearance
Width
10"
0.058-0.059"
Piston Diameter (10 mm from skirt edge) (min)
2.205"
Cylinder/Head Distortion (max)
0.004"
Connecting Rod Small End Bore Inside Diameter
0.6301-0.6307"
Free Length
Connecting Rod Big End Inside Diameter
1.1023-1.1029"
6.97”
Connecting Rod Big End Side Clearance
0.008-0.024"
Cam Lobe Height
1.048-1.052"
Crank Pin Diameter (min)
1.102"
Crank Pin/Connecting Rod Clearance
0.0002-0.0008"
Crankshaft Rod Journal (Out-of-Round/Taper)
0.004"
Crankshaft Runout (t.i.r.)
0.0008"
Valve Guide Inside Diameter (max)
Valve Guide/Stem Clearance (max)
Valve Face Width (min)
Valve Face Runout (max)
0.22"
(Int) 0.0016-0.0020"
(Exh) 0.0020-0.0030"
Lug Height
0.690"
Tension @ 20 lb
1/4-3/8"
Ski Shock Spring
Specifications
(1st) 0.0016-0.0030"
(2nd) 0.0008-0.0024"
Piston Ring Thickness
Idle Fuel Adjuster Screw Float Height
(Turns Out)
1
0.63"
Wire
Diameter
0.235”
Rate LB/Inch
# of Coils
Tab
85
9.0
NO
Rear Arm Spring
Specifications
Wire
Diameter
0.406"
Angle
6°
#of
Coils
4.48
Coil
Width
2.45"
Length
Length
6.03"
4.57"
0.030"
0.0012"
Valve Clearance - Cold (59°-77° F)
(Int/Exh) 0.004"
Valve Seat Contact Width (min)
(Int/Exh) 0.03"
Valve Stem Diameter (min)
(Int/Exh) 0.22"
Valve Stem Runout (max)
0.0004"
Valve Spring Free Length (max)
1.04"
Camshaft End Running Surface (max)
0.592”
Camshaft End Play (max)
0.002”
Ski Shock Absorber
Specifications
Collapsed
Length
7.78”
Extended Length
Stroke
9.49”
1.71”
Piston
Depth
N/A
Idler Wheel Dimensions
Location
Inside Rails
6
O.D.
5.63"
Idler Arm
7.12"
Inside Rear Axle
7.12"
Bearing I.D.
0.787"
1.181"
0.787"
Engine
This engine section has been organized into sub-sections
showing a progression for the complete servicing of the
Arctic Cat 120 cc engine. For consistency purposes, this
section shows a complete and thorough progression;
however, for efficiency it may be preferable to remove
and disassemble only those components needing to be
addressed and to service only those components. Also,
some components may vary. The technician should use
discretion and sound judgment.
IO059A
Removing
4. Pull the steering post up and back and then out of
the lower steering post bearing.
NOTE: The drive chain must be removed in order to
5. Remove the two lock nuts and cap screws securing
the tie rods to the steering post; then remove the tie
rods from the steering post. Place the steering post
out of the way on the right-hand side of the engine
compartment.
remove the engine (see Drive Chain and Sprockets section).
1. Loosen the pinch screw and jam nuts (A) securing
the choke cable to the carburetor; then loosen the
throttle cable jam nuts (B) and remove the cable
from the mounting bracket. Secure the cables out
of the way.
IO060A
6. Cut the cable tie; then disconnect the coil and two
magneto wires at the front of the engine. Route
them out of the way.
IO057A
2. Turn the gas tank shut-off valve to the CLOSED
position; then disconnect the fuel hose from the
carburetor.
! WARNING
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.
3. Remove the two cap screws securing the steering
post to the steering post support. Account for two
bearing halves, two lock nuts, and a bearing
retainer.
A047
7. Pull the recoil starter rope out for enough to tie a
slip-knot in the starter rope below the console and
allow the rope to slowly retract against the recoil
starter.
8. Remove the knot at the handle and remove the
handle; then thread the rope through the bushing in
the console.
7
9. At this point, scribe a line at the front of the engine
and measure the distance between the crankshaft
and the driveshaft. Record the measurement for
installing purposes.
13. Remove the engine from the engine compartment.
Disassembling
1. Remove the oil drain plug and drain the oil; then
install the oil plug and tighten securely.
A048
10. Lay the snowmobile on its side.
NOTE: A piece of cardboard should be used to protect
the finish.
IO063
11. Using a flat-blade screwdriver, remove the four
belly pan plugs covering the engine mounting cap
screws; then remove the cap screws and lock nuts.
2. Remove the cover from the air cleaner case; then
disconnect the breather hose and remove the filter
and retaining plate.
NOTE: The retaining plate is directional.
IO061A
NOTE: The front center plug is to access the oil drain
plug.
12. Place the snowmobile in the upright position; then
on the left-hand side of the engine, remove the
three cap screws securing the engine and brake
bracket to the front end.
IO056A
3. Remove the two cap screws securing the air
cleaner case to the intake tube; then remove the
cap screw and lock nut securing the case to the
throttle cable bracket, remove the air cleaner case
and account for the intake tube gasket.
IO064A
IO062A
8
4. Remove the two springs from the governor arm,
throttle cable bracket, and retaining bracket.
IO068
NOTE: If the cylinder head will be replaced, the carbuIO065A
NOTE: For assembling purposes, note the location of
the governor arm spring before removing.
5. Remove the throttle cable and retaining brackets
from the engine.
retor studs may be removed by tightening the two nuts
against each other; then using a wrench on the inside
nut, remove the stud.
8. Remove the recoil starter/fan housing assembly.
9. Remove the spark plug wire from the spark plug
and remove the spark plug; then remove the cap
screws securing the ignition coil to the crankcase
housing and remove the coil.
IO066A
6. Loosen the governor arm cap screw and remove
the arm; then disconnect the rod and spring from
the carburetor.
IO069A
10. Remove the cylinder head cover; then remove the
air shroud.
IO067A
7. Slide the intake tube and carburetor off the mounting studs. Account for three gaskets and an insulator block.
IO070A
11. Remove the air breather body from the cylinder
head cover. Account for a gasket.
9
IO071
12. Remove the lock nuts and rocker arm pivots securing the rocker arms to the cylinder head.
IO069B
16. Using a flywheel puller, remove the flywheel.
13. Remove the push rods; then remove the push rod
guide plate.
IO074
IO072A
14. Remove the cap screws securing the head to the
cylinder; then remove the head and account for a
gasket and the location of the two dowel pins.
17. Remove the cap screws securing the stator to the
crankcase; then route the stator harness out
through the slot in the crankcase and remove the
stator.
IO075A
IO073
15. Remove the nut securing the flywheel to the
crankshaft and starter pulley.
10
18. Remove the cap screws securing the crankcase
side cover to the crankcase. Account for dowel
pins, gasket, and a crankshaft shim.
21. Rotate the crankshaft until the connecting rod cap
screws are accessible.
IO094B
IO080A
22. Note the relation of the connecting rod journal to
the crankshaft and mark the connecting rod and end
cap for reference during installation; then remove
the cap screws and connecting rod end cap.
IO077
19. With the piston at TDC, scribe an alignment mark
on the gear of the camshaft directly in-line with
the alignment dot on the crankshaft gear.
IO081A
23. Carefully work the connecting rod/piston up and
out of the cylinder; then remove the crankshaft.
NOTE: For assembling purposes, note the arrow mark
on the dome of the piston is directed to the push rod
opening of the cylinder.
IO078A
24. Remove the hairpin clip from the governor control
shaft; then remove the shaft and account for the
washer.
20. Remove the camshaft; then remove the tappets.
Identify the tappets for proper installation.
IO082A
IO079A
25. Inspect the crankshaft and governor control shaft
oil seals for cracks or deterioration; then inspect
the crankshaft bearings for roughness or discoloration and replace if necessary.
11
NOTE: If the seals or bearings of the crankshaft need
to be replaced, see Crankshaft Bearings in Servicing
Components.
Servicing Components
Thoroughly clean all non-electrical components in partscleaning solvent; then remove any carbon buildup from
the cylinder head, piston dome, valves, and valve seats.
Visually inspect all engine components for wear or damage.
CYLINDER HEAD/VALVE ASSEMBLY
NOTE: Remove the valves by pressing down on the
spring retainer and removing the valve keeper. Account
for valve springs, spring retainers, and valve keepers.
Keep all valves and related components as a set.
When servicing valves and cylinder head assembly,
inspect valve seats, head warpage, valve stems, valve
faces, and valve stem ends for pits, burn marks, or other
signs of abnormal wear. Never reuse the intake valve
seal. Always replace the seal.
ATV-1082
2. Maximum runout must not exceed 0.0004" for
both valves.
Measuring Valve Face Width
1. Using a micrometer, measure the width of the
valve face.
NOTE: Discard any valve that fails the listed inspections. Do not grind the valves. If a valve or cylinder
head is damaged, it must be replaced.
Measuring Cylinder Head Distortion
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the
combustion chamber or the sealing surfaces.
ATV-1004
2. Inspect the spark-plug hole for any damaged
threads. Repair damaged threads using a heli-coil
insert.
3. Inspect the cylinder head for flatness using a
straightedge and a feeler gauge. Acceptable distortion must not exceed 0.004".
2. Acceptable valve face width must be at least
0.030".
Measuring Valve Face Runout
1. Mount a dial indicator on a surface plate; then
place the valve stem on a set of V blocks.
2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator.
IO087
Measuring Valve Stem Runout
1. Support each valve stem end with V Blocks; then
check the valve stem runout using a dial indicator.
ATV1082A
3. Rotate the valve in the V blocks.
4. Maximum runout must not exceed 0.0012".
12
Measuring Valve Guide/Valve Stem
Clearance
1. Using a micrometer and small bore gauge, take
diameter readings on the valve stems and inside
the guides.
2. The stem clearance inside the guide must be
within 0.0016-0.0020" for the intake and 0.00200.0030" for the exhaust.
NOTE: Be sure to take readings at more than one
place along the length of each stem and guide.
5. Rotate the valve until the valve and seat are evenly
polished.
6. Clean all compound residue from the valve and
seat.
Valve Springs
1. When the valve springs are weak, the valve and
valve seat fail to form a good seal, thus allowing
gas to leak past the valve seat causing a loss of
power. Whether or not a valve spring is weak can
be determined by its free length.
Lapping Valves
NOTE: Ensure that all carbon has been removed from
the valves.
1. Using a valve lapper, produce a contact pattern on
each valve face by applying a uniform coat of
valve lapping compound to the valve seat and by
rotating and tapping the valve head.
2. Acceptable width of valve seat contact width
(measurement A) must be at least 0.03".
GM128D
2. Minimum valve spring free length must not
exceed 1.04".
NOTE: With the crankshaft at top dead center on the
compression stroke, install the valve springs and
spring retainers; then compress the valve springs and
install the valve keepers.
CAM LOBE WEAR
GEN-0023
Worn cam lobes result in reduced power output. The
limit of cam lobe wear is specified for both intake and
exhaust lobes in terms of cam height to be measured with
a micrometer. Replace the camshaft if not within 1.0481.052".
GEN-0024
NOTE: Do not grind the valves. If a valve is damaged,
it must be replaced.
GEN0028B
3. Lubricate each valve stem with lightweight oil;
then apply a small amount of valve lapping compound to the entire seating face of each valve.
4. Attach the suction cup of a valve lapping tool to
the head of the valve.
13
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.
2. Remove each ring by working it toward the dome
of the piston while rotating it out of the groove.
NOTE: Note the location of each ring for proper installation. When installing new rings, install as a complete
set only.
Cleaning/Inspecting Piston Rings
NOTE: Make a ring-groove cleaning tool by taking an
IO088
Measuring Camshaft End Running
Surfaces
1. Using an outside micrometer, measure the running
surfaces of each end of the camshaft. The measurement should be at least 0.592".
old piston ring and snapping it into two pieces; then
grind the end of the old ring to a 45° angle and to a
sharp edge.
Using a ring-groove cleaning tool, clean carbon from the
ring-grooves. Be sure to position the ring with its tapered
side up.
CAUTION
Improper cleaning of the ring-grooves by the use of
the wrong type of ring-groove cleaner will result in
severe damage to the piston.
Measuring Piston-Ring End Gap
(Installed)
1. Place each piston ring in the wear portion of the
cylinder. Use the piston to position each ring
squarely in the cylinder.
NOTE: When measuring a piston ring, it should be
IO089
2. Inspect the camshaft bosses of the crankcase and
crankcase cover for cracks, discoloration, and
wear.
PISTON ASSEMBLY
placed into the area of the cylinder where wear is least
(the area is about 0.12" from the upper or lower edge of
the cylinder).
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must be within
0.008-0.016" (1st and 2nd rings) or within 0.00790.0157" (oil ring).
NOTE: Oversized pistons are available allowing the
cylinder to be bored oversized.
NOTE: Whenever a piston, rings, or pins are out of tolerance, they must be replaced.
Cleaning/Inspecting Piston
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the dome of the piston.
2. Inspect the piston for cracks in the piston pin,
dome, and skirt areas.
3. Inspect the piston for seizure marks or scuffing.
NOTE: If seizure marks or scuffing is detected, the
piston must be replaced.
4. Inspect the perimeter of each piston for signs of
excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
14
IO083
3. Piston skirt to cylinder clearance must be within
0.0006-0.0016".
4. If the piston/cylinder clearance exceeds the limit,
bore the cylinder and use an oversized piston or
replace both cylinder and piston.
Installing Piston Rings
1. Place the oil ring expander into the bottom groove
of the piston allowing the ends to contact each
other.
CAUTION
IO090
Piston Ring/Groove Clearance
1. Using a thickness gauge, measure the side clearances of the 1st and 2nd rings.
2. If the measurements are not within 0.00160.0030" (1st ring) or 0.0008-0.0024" (2nd ring),
replace both piston and piston rings.
Measuring Piston Skirt/Cylinder
Clearance
Never allow the ends of the oil ring expanders to overlap. This allows a loss of oil control and incorrect tension of the ring.
2. Place one end of the thin oil ring between the top
of the oil ring expander and the ring groove; then
wind the ring around the piston until the ring is
properly seated into the ringland of the piston.
Repeat this procedure for the lower thin oil ring.
3. Position the thin oil ring gaps 90° from the gap of
the oil ring expander and 180° from each other.
1. Measure the cylinder front to back in six places
using a cylinder bore gauge. The amount of wear
is the difference between the largest and smallest
readings. If the determined wear exceeds the limit
indicated, bore to the next oversize by using a boring machine or replace the cylinder.
4. Install the middle and top compression ring with
the I.D. mark directed toward the dome of the piston.
NOTE: The top compression ring can be identified by
the chrome (silver) face of the ring.
CAUTION
Incorrect installation of the piston rings will result in
engine damage.
Measuring Piston Pin Diameter
1. Measure the piston pin diameter at each end and in
the center. If measurement is less than minimum
specifications, the piston pin must be replaced.
2. Piston pin diameter must be within 0.6297-0.6299".
GEN-0032
2. Measure the corresponding piston diameter at a
point 10 mm above the piston skirt at a right angle
to the piston-pin bore. Piston diameter must be at
least 2.205".
IO086
Measuring Piston Pin Bore Diameter
1. Insert an inside dial indicator into the piston-pin
bore. Take two measurements to ensure accuracy.
IO085
2. Piston pin bore must not exceed 0.433".
15
ATV-1069
IO087
NOTE: If the cylinder/cylinder head assembly cannot
4. Inspect the cylinder for pitting, scoring, scuffing,
warpage, and corrosion. If marks are found, repair
the surface using the Ball Hone (see Honing Cylinder sub-section).
CYLINDER/CYLINDER HEAD
be trued, they must be replaced.
Cleaning/Inspecting Cylinder Head
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the
combustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a “helicoil” insert.
3. Place the cylinder head on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using
light pressure, move the cylinder head in a figure
eight motion. Inspect the sealing surface for any
indication of high spots. A high spot can be noted
by a bright metallic finish. Correct any high spots
before assembly by continuing to move the cylinder head in a figure eight motion until a uniform
bright metallic finish is attained.
CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
Cleaning/Inspecting/Measuring
Cylinder Distortion
1. Wash the cylinder in parts-cleaning solvent.
2. Check the gasket surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places. If the
largest reading at any position of the straightedge
exceeds the limit, replace the cylinder.
3. Maximum cylinder distortion must not exceed
0.004".
5. Place the cylinder on the surface plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder in a figure eight
motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a
bright metallic finish. Correct any high spots
before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright
metallic finish is attained.
CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
Honing Cylinder
1. Wash the cylinder in parts-cleaning solvent.
2. Inspect the cylinder for pitting, scoring, scuffing,
and corrosion. If marks are found, repair the surface using the Ball Hone.
NOTE: To produce the proper 45° crosshatch pattern,
maintain a low drill RPM. If honing oil is not available,
use a lightweight, petroleum-based oil. Thoroughly
clean the cylinders after honing using detergent soap
and hot water and dry with compressed air; then immediately apply oil to the cylinder bores. If a bore is
severely damaged or gouged, the cylinder must be
replaced.
3. If any cylinder bore measurement exceeds the
limit, hone the cylinder and install an oversized
piston or replace the cylinder.
MEASURING CONNECTING ROD
SMALL END BORE INSIDE DIAMETER
1. Using a small bore gauge, measure the connecting
rod small end bore inside diameter.
2. Measurement must be within 0.6301-0.6307".
16
MEASURING CONNECTING ROD BIG
END SIDE CLEARANCE
1. Check the connecting rod side clearance by using
a thickness gauge. If the clearance exceeds the
limit, replace the connecting rod or crankshaft.
2. Clearance measurement must be within 0.0080.024".
GEN-0034
3. If the difference between the connecting rod small
end bore inside diameter and the piston pin outside
diameter exceeds the limit, replace both connecting rod and piston pin. The measurements must be
within 0.0001-0.0002" of each other.
GEN-0036
MEASURING CRANK PIN/
CONNECTING ROD CLEARANCE
1. Measure the crank pin diameter. Measurement
must be at least 1.102".
GEN-0035
CRANKSHAFT RUNOUT
1. Support the crankshaft using a set of V blocks; use
a dial indicator to read crankshaft runout.
NOTE: The contact point of the dial indicator should
be on the seal area of the crankshaft.
2. Total indicator reading must not exceed 0.0008".
GEN-0037
2. Measure the connecting rod big end bore inside
diameter. Measurement must be within 1.10231.1029".
GEN-0031
3. If not within specification, either straighten the
crankshaft or replace it.
GEN-0038
3. Measure the crank pin/connecting rod clearance.
Measurement must be within 0.0002-0.0008".
17
CARBURETOR INSULATOR PLATE
1. Inspect for cracks, scoring, pitting, imperfections,
or warping.
2. Inspect the sealing surfaces for trueness by placing
each on the surface plate covered with #400 grit
wet-or-dry sandpaper. Using light pressure, move
both sides in a figure eight motion. Inspect the
sealing surfaces for any indication of high spots or
warping. Correct highs spots by continuing to
move each side in a figure eight motion. Warped
components must be replaced.
GEN-0039
CRANKSHAFT BEARINGS
A932
CAUTION
0744-992
Removing
1. Using a flat-blade screwdriver, carefully work the
oil seal from side-to-side out of the crankcase and
cover.
2. Using a suitable press and with the crankcase or
crankcase cover secured into position, carefully
heat the case; then press the bearings out of the
case.
CAUTION
Never reuse the crankshaft bearings. If the bearings
have been pressed out of the crankcase or crankcase
cover, they must be discarded.
NOTE: Thoroughly clean the bearing areas of the
crankcase and crankcase cover and inspect for any
nicks or imperfections of the bearing bosses of the
case.
Installing
1. Secure the crankcase and press the new bearing
into the boss of the crankcase and crankcase cover.
CAUTION
When installing the new bearings, always press
against the outside race of the bearing.
2. With the bearings installed and using a suitable
seal driver, install the oil seals with the spring side
of the seal facing the bearing; then coat the wear
surfaces of the seals with a film of grease.
18
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surfaces may result.
Assembling
NOTE: The use of new gaskets and seals is recommended when assembling the engine.
NOTE: Prior to assembling the engine, use parts
cleaning solvent and compressed air and thoroughly
clean the threaded holes of the crankcase and cylinder
and head to properly tighten.
! WARNING
Always wear safety glasses when drying components
with compressed air.
NOTE: When the use of a lubrication is indicated, use
clean engine oil.
1. Lubricate the piston pin, connecting rod, and piston pin bore with engine oil; then install the piston
to the connecting rod and secure the piston pin
with the circlips directed either up or down.
4. With the connecting rod, end cap, and crankshaft
journal lubricated with engine oil, install the connecting rod and rod end cap to the crankshaft and
secure with the cap screws. Tighten evenly to 106
in.-lb.
IO091A
NOTE: Coat the cylinder wall, connecting rod bearing
surface, and the crankshaft with engine oil.
2. Install the crankshaft into the crankcase; then with
the piston rings properly oriented (end gap 120°
apart), compress the piston rings and install the
piston and connecting rod assembly taking care
not to damage the crankshaft and connecting rod.
IO080A
5. Apply lightweight oil to the tappets; then install
the tappets to the proper guides as noted during
disassembly.
CAUTION
The arrow of the piston must be directed towards the
push rod opening of the cylinder.
IO079A
0745-001
3. Note the marks on the connecting rod and end cap
made during disassembly.
6. Apply oil to the camshaft lobes and running surfaces on each end of the shaft; then with the crankshaft/piston rotated to TDC and the timing marks
of the crankshaft gear in-line with the camshaft
gear, install the camshaft.
IO078A
IO081A
NOTE: When installing the connecting rod to the
crankshaft, rotate the crankshaft so the rod journal is in
the six o’clock position to allow access for installing
the rod end cap.
7. Install the washer onto the governor control shaft
and slide the shaft up into position from inside the
crankcase far enough to install the hairpin clip.
19
IO101
IO077
NOTE: When installing the governor control shaft,
9. Secure the crankcase side cover to the crankcase
with the cap screws. Tighten to 16 ft-lb using the
following pattern.
position the shaft so the flat end (A) of the shaft is
directed to the cylinder (3 o’clock position) and the hairpin clip (B) is in contact with the crankcase. This limits
the inward movement of the control shaft.
IO094A
NOTE: Before installing the side cover, verify the govIO082B
ernor gear assembly operates properly.
10. Install the dowel pins and a new gasket; then
secure the head to the cylinder with the cap
screws. Tighten to 15 ft-lb using a crisscross pattern.
IO093A
8. Install the shim washer to the crankshaft and place
the dowel pins and a gasket into position.
IO073
11. Apply lightweight oil to the ends of the push rods;
then install the rods.
12. Loosely secure the rocker arms to the cylinder
head with the pivots and lock nuts; then rotate the
crankshaft until the piston is at the top of the compression stroke.
20
IO107
IO096A
13. Set the valve clearance to the recommended setting with a feeler gauge, and while holding the
adjustment nut, tighten the rocker arm lock nuts to
88 in.-lb. Verify valve clearance is 0.004".
NOTE: Adjust spark plug gap to specification; then
14. Install the air shroud to the cylinder head and
secure the shroud with cap screw. Tighten to 96
in.-lb.
install and tighten the plug to 15 ft-lb.
17. Connect the high tension lead to the spark plug
and secure with the two wire forms.
18. Install the stator with the four cap screws (coated
with blue Loctite #243) and in a crisscross pattern,
tighten to 96 in.-lb.
IO098A
15. Place the air breather body assembly with gasket
onto the cylinder head cover; then install the valve
cover with gasket. Tighten to 96 in.-lb using a
crisscross pattern.
IO097A
NOTE: Route the stator harness through the slot in
the crankcase above the flywheel.
19. With the flywheel key in the crankshaft, install the
flywheel and starter pulley; then secure with the
nut. Tighten to 48 ft-lb.
IO070A
16. Install the ignition coil to the mounting location of
the crankcase with the cap screws (coated with
blue Loctite #243); then adjust the ignition coil to
the farthest position from the flywheel and tighten
the cap screws until snug.
IO069B
NOTE: Before installing the flywheel, make sure the
taper of the crankshaft and flywheel are clean.
21
20. Rotate the flywheel until the magnet of the flywheel is under the legs of the ignition coil; then
insert a flat 0.020" feeler gauge between the lower
leg of the coil and the flywheel.
IO102A
! WARNING
When performing service work on the fuel system, do
not smoke or allow open flames near the snowmobile.
IO099
21. Loosen the ignition coil mounting cap screws
(from step 16) enough to allow the coil to draw
against the feeler gauge. Tighten the cap screw
enough to hold the position of the coil; then repeat
the procedure for the other cap screw when an air
gap of 0.015-0.023" is obtained. Tighten the coil
cap screws to 120 in.-lb.
25. Install the rod and spring into the governor control
arm and install the arm; then install the throttle
lever spring into the proper hole of the control arm
(as noted during disassembling) and the remaining
spring to the retaining bracket.
22. Install the recoil starter/fan housing assembly with
cap screws and tighten to 96 in.-lb.
IO065A
NOTE: When securing the governor control shaft (A),
turn it clockwise until it stops; then tighten the control
arm cap screw (B) to 72 in.-lb.
IO100A
23. Install the throttle cable mounting bracket and
secure the bracket with two cap screws to the
crankcase. Tighten to 120 in.-lb.
IO067B
26. Install the gasket onto the mounting studs; then
install the intake tube to the carburetor. Tighten to
96 in.-lb.
IO105
24. Install the carburetor (with a gasket, insulator
block, and a gasket) onto the mounting studs; then
install the rod and spring (A) onto the carburetor.
22
IO104
IO062A
27. With a gasket in place on the intake tube, install
the air cleaner case, and with gasket, insulator
plate, and cap screws, secure the case to the intake
tube and tighten the cap screws to 120 in.-lb.
Install the cap screw and lock nut securing the case
to the throttle cable bracket and tighten to 12 ft-lb.
3. Align the engine with the scribed line made during
removing; then measure the distance between the
crankshaft and the driveshaft. Adjust the engine
position as necessary.
4. Tighten the three left-hand side mounting cap
screws (from step 2) to 20 ft-lb.
5. Lay the snowmobile on its side and install the four
lower engine mounting cap screws with washers
and lock nuts. Tighten to 20 ft-lb.
6. Install the four mounting cap screw plugs in the
belly pan; then place the snowmobile in the
upright position.
7. Thread the recoil starter rope through the bushing
in the console and the handle; then tie a knot at the
end of the rope and pull the handle up and onto the
knot.
IO064A
28. Install the retaining plate and fitting; then secure
the air cleaner cover to the air cleaner case with
the two screws. Tighten to 96 in.-lb.
29. Add 20.3 fl oz of the recommended engine oil to
the engine.
8. Untie the slip-knot at the starter case and allow it
to slowly rewind into the case.
9. Install the tie rods on the steering post; then secure
with lock nuts (threads coated with green Loctite
#609) and washers. Tighten to 20 ft-lb.
10. Place the steering post in position in the lower steering post bearing and on the steering post support.
Installing
1. Place the engine assembly into position in the
engine compartment.
2. On the left-hand side of the engine, install the
three cap screws (coated with blue Loctite #243)
securing the engine and brake bracket to the front
end. DO NOT TIGHTEN AT THIS TIME.
A025
11. Place the upper steering post bearing into position
on the steering post and support; then secure with
the bearing retainer, cap screws, and lock nuts.
23
Changing Oil
NOTE: The front of the snowmobile must be elevated
until the bottom of the front bumper is approximately
18.5" from the floor so the engine is in a level position
when checking/changing the oil. Also, assure the
engine is “cooled down” to room temperature to allow
the oil to drain into the sump.
IO060A
12. Position the throttle cable in the bracket; then connect the cable to the throttle lever. Tighten the
adjustment jam nuts securely.
0744-920
1. Remove the access plug; then place a drain pan
beneath the engine.
2. Using a flat-blade screwdriver, release the hood
latch; then release the two hold-down straps and
open the hood.
IO057B
NOTE: At this point, install the drive chain (see Drive
Chain and Sprockets section).
13. Install the choke cable into the bracket and carburetor butterfly arm. Adjust the cable and secure
with the jam nuts and pinch screw.
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; then tighten to 12 ft-lb.
5. Remove the oil level stick; then pour 600 ml (20.3
fl oz) of recommended oil into the fill hole.
6. Install the oil level stick; then install the access
plug.
7. Close the hood and secure with the straps and
latch.
Recoil Starter
IO106A
14. Install the breather tube into the air cleaner case.
15. Connect the engine wiring harness to the main
wiring harness; then secure the wiring harnesses
with a cable tie.
16. Connect the fuel hose to the carburetor; then turn
the gas tank shut-off valve to the OPEN position.
KEY
A.
B.
C.
D.
E.
F.
G.
Cap Screw
Reel
Shoulder Screw
Drive Plate
Ratchet Arm Set
Friction Spring
Spiral Spring
0745-012
24
NOTE: The engine must be removed to access the
recoil starter (see Engine section).
REMOVING/DISASSEMBLING
! WARNING
Always wear safety glasses when servicing the recoil
starter.
1. Remove the cap screws (A) securing the recoil
starter to the engine cover.
INSPECTING
1. Inspect the spring retaining notch in the recoil
housing and inspect the loop of the spring for wear
or cracking.
NOTE: Note the orientation of the spring for assembling purposes.
2. Inspect the flat areas of the reel for wear.
ASSEMBLING/INSTALLING
2. Pull the rope out of the housing (noting the direction in which the rope is wound for assembling)
and align with the notch in the roller; then release
the spring pressure on the reel (B).
1. Install the reel assembly with rope wound in the
appropriate direction (noted during disassembling).
3. Remove the knot from the end of the rope; then
remove the shoulder screw (C) securing the drive
plate (D) to the reel and remove the plate.
Exercise extreme caution when installing as the spiral
spring may disengage and cause severe injury.
4. Mark the ratchet arms (E) for assembling purposes;
then remove the ratchets and account for the friction
spring (F).
NOTE: The ratchet arms must be installed in their
respective positions.
5. Slowly remove the reel. Account for the spiral
spring (G).
! WARNING
! WARNING
2. Install the ratchet arms; then install the drive plate
and secure it with the shoulder screw. Tighten to
57 in.-lb.
3. Route the recoil rope through the rope guide of the
recoil housing and through the recoil handle; then
tie a knot in the rope.
4. Wind the rope counterclockwise 3-4 turns around
the reel; then secure the recoil starter to the engine
cover. Tighten to 96 in.-lb.
Exercise extreme caution when removing as the spiral
spring may disengage and cause severe injury.
25
Troubleshooting Engine
Problem: Engine Does Not Start (No Spark at Spark Plug)
Condition
Remedy
1. Check all ground connections — clean and tight
1. Ground connections dirty — loose
2. Repair — replace — connect wiring harness
2. Wiring harness shorting — disconnected
3. Emergency stop switch in DOWN position — malfunctioning 3. Move switch to UP position — test/replace key switch/emergency stop switch
4. Tether cord improperly secured to tether switch — malfunc- 4. Properly secure cord to the switch — test/replace switch
tioning
5. Clean — replace spark plug
5. Spark plug fouled — damaged
Problem: Engine Does Not Start (No Fuel at Cylinders)
Condition
1.
2.
3.
4.
5.
6.
Gas tank empty
Gasoline contaminated
Fuel hose broken — pinched
Gas-tank vent — hose obstructed
Shut-off valve obstructed — damaged
Compression absent
Problem: Engine Does Not Start (Fuel Does Not Ignite)
Condition
1.
2.
3.
4.
Valve clearance poor
Spark absent
Compression low
Engine flooded
5. Gasoline contaminated
Problem: Engine Does Not Idle
Condition
1.
2.
3.
4.
Throttle stop screw turned out too far
Idle fuel adjuster screw out of adjustment
Air silencer obstructed
Drive clutch dirty
Problem: Engine Loses Power
Condition
1.
2.
3.
4.
5.
Spark plug fouled
External coil faulty
Gas tank vent — hose obstructed
Compression low
Muffler restricted
Problem: Engine Overheats
Condition
1.
2.
3.
4.
5.
Drive system adjusted incorrectly — worn — damaged
Rings/grooves carboned
Exhaust obstructed
Compression low — absent
Engine shroud obstructed
Problem: Engine Backfires
Condition
1. Spark plug fouled — damaged
Problem: Engine Stops Suddenly
Condition
1.
2.
3.
4.
5.
6.
7.
8.
26
Gas tank empty
Spark absent
Fuel filter obstructed
Gas tank shut-off valve in OFF position
Fuel hose obstructed — broken — pinched
Ignition coil faulty
Engine seized
Oil level low
Remedy
1.
2.
3.
4.
5.
6.
Fill tank
Replace gasoline
Replace — service hose
Remove obstruction — replace vent — hose
Remove obstruction — replace shut-off valve
Repair — replace damaged — worn engine components
Remedy
1.
2.
3.
4.
Inspect valves
Check for spark — see No Spark at Spark Plug sub-section
Service engine
Clear engine (using a shielded safety stand, elevate the rear
of the snowmobile and hold throttle full-open)
5. Clean tank and entire fuel system
Remedy
1.
2.
3.
4.
Adjust throttle stop screw
Adjust idle fuel adjuster screw
Clean air silencer
Clean drive clutch
Remedy
1.
2.
3.
4.
5.
Replace spark plug
Service — replace coil
Service — replace vent hose
Service engine
Inspect muffler
Remedy
1.
2.
3.
4.
5.
Troubleshoot — adjust drive system
Clean — replace rings — pistons
Remove obstruction
Repair — replace damaged — worn engine components
Clean shroud
Remedy
1. Clean — replace spark plug
Remedy
1.
2.
3.
4.
5.
6.
7.
8.
Fill tank
See No Spark at Spark Plug sub-section
Replace filter
Turn on valve
Remove obstruction — repair — replace fuel hose
Replace ignition coil
Overhaul engine
Add recommended oil
REMOVING
Fuel System
NOTE: Before removing the carburetor, be sure the
gas tank shut-off valve is in the OFF position.
This section has been organized for servicing the fuel
system. The technician should use discretion and sound
judgment when removing/disassembling and assembling/
installing components.
1. Remove the screws securing the air cleaner cover
to the air cleaner case and account for the filter and
retaining plate.
! WARNING
2. Remove the flanged nuts securing the air cleaner
assembly to the carburetor and engine.
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.
Pre-Maintenance Checks
3. Remove the air cleaner case and intake tube from
the carburetor and engine. Account for the gasket.
4. Remove the drain screw w/spring (I) from the float
chamber and drain any gasoline from the chamber;
then install the drain screw w/spring.
5. Remove the fuel supply hose.
Before troubleshooting the fuel system, several simple
checks should be performed. Many times what appears to
be a serious problem is only a minor one.
6. Disconnect the rod and spring from the carburetor;
then loosen the pinch screw and jam nuts securing
the choke cable to the carburetor.
1. Make sure the gas tank shut-off valve was in the
OPEN position and check for fuel flow from the
tank to the carburetor.
7. Slide the carburetor off the mounting studs.
Account for a gasket, insulator, and a gasket.
DISASSEMBLING
2. Turn the shut-off valve to the CLOSED position;
then remove the in-line fuel filter. If the filter is
dirty, replace the filter.
3. Install a new filter making sure the arrow on the
filter is directed toward the engine.
4. Check the gas tank fuel and vent hoses to ensure
that all are correctly connected; then check for
cracks. If any cracks are evident in the hoses,
replace them making sure none are against any hot
or moving parts. Hoses must fit tightly.
5. Check the carburetor float chamber by loosening
the drain screw (I) and inspect it for water or
debris. If seen, clean by removing the float chamber cap screw and cleaning the float chamber.
6. When ready for operation, turn the shut-off valve
to the OPEN position.
744-959A
1. Carefully remove the plastic cap from the idle fuel
adjuster screw (A); then rotate the screw clockwise while noting the number of rotations (for
assembling purposes) until lightly seated. Remove
the screw.
Carburetor
CAUTION
Do not force the idle fuel adjuster screw when rotating
it clockwise; damage to the screw taper and carburetor orifice may result.
2. Remove the pilot jet (B) from the carburetor.
3. Remove the cap screw (C) securing the float
chamber to the carburetor; then remove the chamber and account for the rubber gasket.
744-908A
27
4. Remove the float pin (D) securing the float (E) to
the carburetor body; then remove the float and
needle jet assembly (F).
5. Remove the main jet (G) and the nozzle (H) from
the carburetor tower.
7. Place the carburetor insulator on a surface plate
covered with #400 grit wet-or-dry sandpaper.
Move the insulator over the surface plate using a
figure eight motion. The motion should produce
an even wear pattern over the entire sealing area.
CAUTION
CLEANING
CAUTION
DO NOT place any non-metallic components in partscleaning solvent or carburetor cleaner because damage or deterioration will result.
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surfaces may result.
1. Place all metallic components in a wire basket and
submerge in carburetor cleaner.
2. Soak for approximately 30 minutes; then rinse
with fresh parts-cleaning solvent.
3. Wash all non-metallic components with soap and
water. Rinse thoroughly.
4. Dry all components with compressed air only
making sure all holes, orifices, and channels are
unobstructed.
5. Blow compressed air through all hoses to remove
any obstructions.
! WARNING
Always wear safety glasses when drying components
with compressed air.
CAUTION
DO NOT use wire or small drill bits to clean carburetor
orifices, holes, or channels. Distorted or damaged orifices, holes, or channels can result in poor carburetor
operation.
A739
8. Inspect the condition of the throttle return spring.
CHECKING FLOAT HEIGHT
1. Remove the cap screw securing the float chamber;
then remove the float chamber from the carburetor
and account for the rubber gasket.
2. With the carburetor in an upside-down position,
lift the float so the tip of the float lightly contacts
the float arm; then measure the float height from
the body of the carburetor and under-side of the
float. Measurement should be 0.63".
INSPECTING
1. Inspect the mixing body and jet orifices for cracks,
nicks, stripped threads, and any other imperfections in the casting.
2. Inspect the float for perforations or damage.
3. Inspect the gaskets for distortion, tears, or noticeable damage.
4. When applicable, inspect the idle fuel adjuster
screw, needle jet assembly, and pilot jet for wear,
damage, or distortion.
5. Inspect the nozzle and main jet for obstructions or
damage.
6. Inspect the carburetor insulator for damage,
cracks, and tightness.
CAUTION
An air leak between the carburetor and engine will
cause a lean condition and poor engine performance.
28
IO108
CAUTION
Do not bend the float in an attempt to adjust the
height. Correct float height is obtained by replacing
the needle jet assembly and/or the float.
ASSEMBLING
2. Install the choke cable and secure the cable with
the jam nuts and pinch screw.
3. Install the fuel supply hose on the carburetor.
4. Place the gasket and air cleaner assembly into
position on the carburetor; then secure with the
flanged nuts and cap screw.
5. Secure the air cleaner cover to the air cleaner with
the screws. Tighten to 96 in.-lb.
6. Turn the gas tank shut-off valve to the OPEN position and check the fuel system for leakage.
7. Adjust the carburetor (see ADJUSTING sub-section).
ADJUSTING
744-959A
1. Install the nozzle (H) and main jet (G) into the carburetor tower.
2. Place the needle jet assembly (F) and the float (E)
into position and secure to the carburetor body
with the float pin (D).
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, three external adjustments can be made on the
carburetor. These are the throttle stop screw, idle fuel
adjuster screw, and throttle cable.
3. Secure the float chamber w/rubber gasket to the
carburetor with the cap screw (C).
4. Install the pilot jet (B).
5. Install the idle fuel adjuster screw (A) and rotate
the screw clockwise until lightly seated; then
rotate the screw counterclockwise the proper number of rotations as noted during disassembling.
Install the plastic cap.
CAUTION
Do not force the idle fuel adjuster screw when rotating
it clockwise; damage to the screw taper and carburetor orifice may result.
INSTALLING
1. Install the gasket, insulator, and a gasket; then
with the governor rod and spring installed on the
carburetor, place the carburetor into position on
the mounting studs. Install the flanged nuts and
tighten to 96 in.-lb.
0744-921
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 screw determines the fuel/air mixture for idling. To
adjust, use the following procedure:
1. Start the engine and allow to run at half throttle 510 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.
GF318D
29
Speed Control Screw
IO110B
Throttle Cable
0744-949
The correct throttle cable adjustment is when (with the
engine OFF) the carburetor throttle is completely open
(against its limit) while the throttle lever lightly contacts
the handlebar grip. The throttle arm on the carburetor
should also contact the speed control screw when the
throttle lever is released.
1. To adjust the throttle cable, loosen the throttle
cable jam nuts.
The maximum speed of the snowmobile can be reduced
by adjusting the speed control screw.
To reduce the maximum speed, rotate the speed control
screw clockwise. DO NOT EVER INCREASE THE
MAXIMUM SPEED BEYOND THE ORIGINAL 8
MPH MAXIMUM.
Throttle Cable
! WARNING
Do not attempt to adjust the throttle cable with the
engine running. Personal injury could result.
REMOVING AND INSPECTING
1. Remove the C-clip securing the lever pin in the
throttle lever; then remove the pin and the lever.
0744-922
2. Pull all slack from the throttle cable wire and exert
slight tension on the wire.
3. Tighten the throttle cable jam nuts.
A979
2. Disconnect the throttle cable from the lever; then
slide the cable out of the lever.
! WARNING
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.
A980
30
3. Remove the C-clip securing the cable in the throttle control; then remove the cable from the throttle
control.
6. Inspect the throttle cable for damage or fraying.
INSTALLING
1. Route the cable through the slot in the throttle control and insert the cable into the throttle control.
Secure the cable with a C-clip.
A981
A981
2. Seat the cable drum into the throttle lever recess;
then secure the throttle lever to the throttle control
with a pin and C-clip.
A982
4. Remove the handlebar pad and cut the cable tie
securing the throttle cable to the steering post.
NOTE: Note the location of the cable tie for assembly.
5. Rotate the throttle cable lever of the governor control arm to the wide-open position and route the
cable end out of the arm; then loosen the throttle
cable jam nuts and remove the throttle cable.
A980
3. Place the throttle cable into the throttle cable
bracket and secure with jam nuts.
4. Slide the end of the throttle cable into the throttle
cable lever.
5. Secure the throttle cable to the steering post with a
cable tie; then install the handlebar pad.
6. Open and close the throttle lever to make sure of
no binding or sticking.
NOTE: At this point, adjust the throttle cable (see
Throttle Cable in the Carburetor sub-section).
ADJUSTING
0744-922
To adjust the throttle cable, see Carburetor – ADJUSTING sub-section.
31
Troubleshooting Fuel
System
Problem: Carburetor Too Rich (0-1/4 Opening)
Condition
Remedy
1.
1. Choke valve will not seat
2.
2. Idle fuel adjuster screw out of adjustment
3. Float/needle jet obstructed — damaged — adjusted incor- 3.
rectly
4.
4. Pilot jet loose
Problem: Carburetor Too Rich (1/4-3/4 Opening)
Condition
Adjust — service — replace choke cable — assembly
Adjust idle fuel adjuster screw
Remove obstruction — replace needle jet — float
Tighten pilot jet
Remedy
1. Replace pilot jet
1. Pilot jet too large
2. Float/needle jet obstructed — damaged — adjusted incor- 2. Remove obstruction — replace needle jet — float
rectly
3. Tighten — replace main jet
3. Main jet loose — too large
4. Remove obstruction
4. Primary air passage obstructed
Problem: Carburetor Too Rich (3/4-WOT Opening)
Condition
Remedy
1. Main jet loose — too large
1. Tighten — replace with smaller main jet
2. Float/needle jet obstructed — damaged — adjusted incor- 2. Remove obstruction — replace needle jet — float
rectly
Problem: Carburetor Too Lean (0-1/4 Opening)
Condition
Remedy
1. Adjust — service choke cable — valve assembly
1. Choke valve hanging open
2. Remove obstruction
2. Pilot jet — outlet obstructed
3. Float/needle jet obstructed — damaged — adjusted incor- 3. Remove obstruction — replace needle jet — float
rectly
Problem: Carburetor Too Lean (1/4-3/4 Opening)
Condition
Remedy
1. Pilot jet — outlet — main jet obstructed
1. Remove obstruction
2. Float/needle jet obstructed — damaged — adjusted incor- 2. Remove obstruction — replace needle jet — float
rectly
Problem: Carburetor Too Lean (3/4-WOT Opening)
Condition
Remedy
1. Main jet obstructed — too small
1. Remove obstruction — replace with larger main jet
2. Float/needle jet obstructed — damaged — adjusted incor- 2. Remove obstruction — replace needle jet — float
rectly
Problem: General Fuel System (Engine Cuts Out at High RPM)
Condition
Remedy
1.
2.
3.
4.
32
Fuel delivery inadequate
In-line fuel filter obstructed — damaged
Gasoline contaminated
Gas-tank vent — hose obstructed
1.
2.
3.
4.
Repair — replace hose
Remove obstruction — replace in-line fuel filter
Replace gasoline — de-ice — clean carburetor
Remove obstruction — replace vent — hose
Electrical System
TESTING COMPONENTS
Following are testing procedures for specific electrical
components. All tests of the electrical components
should be made using the digital Fluke Model 77 Multimeter. Replace any component that does not have a test
value within specifications.
NOTE: Whenever using a digital-style tester, “open
(infinite resistance)” denotes an overload and the meter
reading will be OL since the meter is not calibrated to
register resistance values of that magnitude.
NOTE: Whenever testing switches, less than 1 ohm is
As the flywheel turns faster, the primary current
increases, and the terminal voltage of the circuit consisting of the resistor (R) and the transistor (TR1) increases.
This increases the working voltage at the connection of
the series circuit (r1 + r2) connected in parallel to the primary circuit. As the flywheel turns further, the terminal
voltage of the resistor (r2) in the resistor circuit (r1 + r2)
rises to the level of working voltage of the transistor
(TR2) when the ignition timing approaches the rated
RPM, and, thus, the transistor (TR2) is turned on. As a
result, the base current of (TR1) flowing through the
resistor (R) is by-passed, and the transistor (TR1) is
turned off from the conductive state.
The current flowing through the primary winding (2) is
thus interrupted, and rapid change occurs in the magnetic
flux across the ignition coil. The result is a high surge
voltage in the secondary winding (3).
desirable with the switch in the activated position.
SPARK ADVANCE CHARACTERISTIC
NOTE: Always check the appropriate fuse before test-
As noted above, the unit circuit detects a voltage and
makes switching to produce a high voltage required to
produce a spark. On the other hand, the wave form of the
voltage generated in the primary winding changes as the
flywheel turns.
ing a component for failure.
Transistorized Ignition
System
The transistorized ignition system has no contact points.
Therefore, this ignition system does not require periodic
reconditioning of contact point surfaces or point gap
adjustment. As a result, a strong spark is produced even
at low speeds so maximum reliability can be ensured.
The working voltage (VS) of the unit circuit is at level A
when the engine is started, but as the engine speed
increases, the wave form of the voltage changes and
advances to level B.
OPERATION
GEN-0009
TROUBLESHOOTING
GEN-0008
When the recoil starter handle is pulled, the flywheel is
turned. An electromotive force generated in the primary
winding of the ignition coil makes the transistor (TR1)
conduct through the resistor (R) and forms the primary
circuit (indicated by dashed lines).
1. Remove the spark plug and visually check its condition. Replace if fouled. Adjust spark plug gap to
0.028-0.031". Attach the high tension lead to the
spark plug and ground the plug on the cylinder head.
NOTE: Make sure the emergency stop switch is in the
ON (UP) position, the ignition switch is in the RUN position, and the tether cord is connected to the tether switch.
2. Crank the engine over and check for a spark. If no
spark is present, disconnect the main wiring harness from the engine. Crank the engine over. If
spark is now present, the problem is either one or
more of the following items.
A. Defective ignition switch
B. Defective emergency stop switch
C. Defective wiring harness
33
3. Connect one tester lead to one end of the cap and
the other tester lead to other end of the cap.
D. Defective tether
Testing Ignition Switches
1. Disconnect the engine wires from the main wiring
harness.
2. At the main wiring harness engine connector, connect
the red tester lead to the violet wire; then connect the
black tester lead to the engine ground (brown wire).
3. With the ignition switch in the RUN position, the emergency stop switch in the ON position, and the tether
cord connected, the meter must read no resistance. If
the meter reads resistance, disconnect the ignition
switch from the main wiring harness. If the meter now
reads no resistance, replace the ignition switch.
B170
4. Spark plug cap resistance must be between 40006000 ohms.
MAGNETO
1. Disconnect the two white wires from the main harness.
2. Set the meter selector to the OHMS position; then
connect the red and black tester leads to each of
the two white wires.
3. The meter must show less than 1 ohm.
EXTERNAL COIL
Primary
725-704A
4. If the meter continues to read resistance with the
ignition switch disconnected, disconnect the emergency stop switch. If the meter now reads no resistance, replace the emergency stop switch.
5. If the meter continues to read resistance with both
the ignition switch and the emergency stop switch
disconnected, disconnect the wires to the tether
switch. If the meter now reads no resistance,
replace the tether switch.
6. If the meter continues to read resistance with all
three switches disconnected, replace the main wiring harness.
Testing Electrical
Resistances
NOTE: The following test procedure starts by testing
1. Disconnect the single black/white wire lead of the
coil from the main harness.
2. Set the meter selector to the OHMS position; then
connect the red tester lead to the black/white wire
and the black tester lead to the metal post of the
coil.
3. Resistance must be within 11.25-11.75k ohms.
Secondary
1. Remove the spark plug end cap from the high tension lead of the coil.
2. Set the meter selector to the OHMS position; then
connect the red lead of the tester to the high tension lead fo the coil and the black tester lead to
ground.
3. Resistance must be within 6000-7000 ohms.
LIGHTING COIL
the resistance for the spark plug cap and working back
to the stator under the flywheel. Replace any component that does not have a test value within specifications.
1. Disconnect the two yellow wires from the main
wiring harness.
SPARK PLUG CAP
3. Connect the tester leads to the two yellow leads on
the engine-side connectors.
1. Remove the spark plug cap from the high tension
lead by rotating it counterclockwise.
2. Set the selector in the OHMS position.
34
2. Set the selector to the OHMS position.
4. Lighting coil resistance must be between 0.460.68 ohm.
Drive Chain and
Sprockets
REMOVING
1. Remove the self-tapping screws securing the front
clutch shield and rear sprocket cover; then remove
from the engine compartment. Note the position of
the hood cable.
NOTE: It will be necessary to reinstall the hood cable
once the guard is removed.
IO112A
2. Remove the muffler hold-down spring from the
muffler and support bracket; then remove the two
nuts securing the muffler to the engine.
6. Secure the centrifugal clutch with a pair of channel-lock pliers at the outer clutch collar; then
remove the cap screw securing the clutch. Account
for a lock washer, washer, and a spacer.
IO111A
A020
3. Press down on the muffler and pull it to the side
until the muffler flange clears the engine exhaust
studs; then remove the muffler from the engine
compartment. Account for the exhaust gasket.
4. Compress and hold the brake lever; then remove
the cap screw and washer securing the chain
sprocket to the driveshaft. Release the lever.
IO113
7. Slide the chain sprocket and clutch (with the drive
chain) off the respective shafts and remove from
the engine compartment. Account for the rear
driveshaft key.
CLEANING AND INSPECTING
IO118A
5. Remove the retaining ring (A) securing the brake
band. Account for a washer; then loosen the rear
brake cable adjustment jam nut (B) and slide the
cable out of the brake bracket. Set the band assembly aside.
1. Thoroughly wash all metallic components in partscleaning solvent. Dry using compressed air.
2. Wash all non-metallic components with soap and
water.
3. Inspect the sprocket driveshaft for damage or for
stripped threads.
4. Inspect the keyways in the driveshaft, chain
sprocket, and clutch for wear or damage.
35
5. Inspect the chain and chain sprocket for wear or
damage.
6. Inspect the driveshaft sprockets for wear or damage.
INSTALLING
1. Slide the chain sprocket/clutch/drive chain assembly into position; then install the key into the new
sprocket.
4. Compress and hold the brake lever; then install the
cap screw (coated with red Loctite #271) and
washer securing the chain sprocket. Tighten the
cap screw to 20 ft-lb; then release the lever.
5. Place the exhaust gasket into position on the
engine exhaust studs.
6. Place the muffler into position in the engine compartment; then press down on the muffler and
position the flange onto the engine exhaust studs.
Secure with two nuts and the hold-down spring.
7. Place the front clutch shield and rear sprocket
cover into position making sure the hood cable is
properly positioned. Tighten the self-tapping
screws securely.
Track and Driveshaft
NOTE: The skid frame must be removed for this proIO114A
2. Secure the clutch with a pair of channel-lock pliers at
the outer clutch collar; then install the cap screw with
lock washer, washer, and spacer. Tighten to 20 ft-lb.
cedure (see Rear Suspension section).
REMOVING
1. Remove the self-tapping screws securing the rear
sprocket cover; then remove the cover.
2. Compress and hold the brake lever; then remove
the cap screw and washer securing the chain
sprocket to the driveshaft. Release the lever.
A020
3. Slide the brake band over the clutch and secure the
brake band with a washer and retaining ring (A);
then with the brake cable installed in the bracket,
tighten the rear brake cable adjustment jam nut (B)
securely.
IO118A
3. Slide the chain sprocket off the driveshaft and set
aside. Account for the key.
IO112A
IO114A
36
4. Remove the cap screws securing the upper idler
wheel assembly to the tunnel; then remove the
assembly from the tunnel.
4. Inspect the keyways in the driveshaft and in the
chain sprocket for wear or damage.
5. Inspect the chain and chain sprocket for damage or
wear.
6. Inspect the track drive sprockets for wear or damage.
INSTALLING
KEY
1.
2.
3.
4.
IO115A
5. Remove the four lock nuts securing the drive
sprocket bearings to the tunnel; then remove the
four carriage bolts from the tunnel.
5.
6.
7.
8.
9.
10.
11.
12.
Spacer
Carriage Bolt
Bearing
Track Drive
Assy
Drive Sprockets
Driveshaft
Key
Chain Sprocket
Lock Nut
Cap Screw
Washer
Chain
742-425A
1. Tip the snowmobile on its side; then place the
track into position in the tunnel.
A021
6. Position the bearing flanges so they are directed
towards the rear; then spread the tunnel slightly
and slide the driveshaft assembly out of the tunnel.
A022
CAUTION
A piece of cardboard should be used to protect the finish on the hood.
2. Slide the driveshaft assembly into position in the tunnel; then secure the drive sprocket bearings with carriage bolts and lock nuts. Tighten lock nuts to 15 ft-lb.
A022
7. Remove the track from the tunnel.
INSPECTING
1. Inspect the driveshaft for damage and for stripped
threads.
2. Inspect the bearings for roughness or damage.
3. Inspect the track for cuts, gouges, or wear.
A021
37
3. Place the upper idler wheel assembly into position
in the tunnel; then secure with cap screws. Tighten
securely.
4. Install the skid frame (see Rear Suspension section).
5. Place the snowmobile in the upright position.
6. Place the key on the driveshaft; then slide the
chain sprocket w/chain onto the driveshaft. Secure
with a cap screw (coated with red Loctite #271)
and washer. Tighten to 20 ft-lb.
7. Inspect the chain for proper engagement with the
clutch sprocket and the chain sprocket.
8. Inspect that the chain tensioner assembly is in
place and functioning properly.
9. Install the rear sprocket cover and secure with the
self-tapping screws. Tighten securely.
0744-945
Adjusting
1. Loosen the idler wheel cap screws.
2. Loosen the rear idler wheel adjusting bolt jam nuts.
NOTE: At this point, proceed to TRACK TENSION subsection.
TRACK TENSION
NOTE: Track tension and track alignment are interrelated; therefore, always check both, even if only one
adjustment seems necessary.
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.
! WARNING
Track tension must be properly maintained. Personal
injury could result if a track is allowed to become
excessively loose.
Checking
! WARNING
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 frame.
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. If the
measurement is not within 1/4-3/8 in., an adjustment is necessary.
38
0744-947
NOTE: To ensure proper track tension adjustment, perform all adjustments on both sides of the snowmobile.
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 sub-section).
6. When proper track tension is obtained, tighten the
adjusting bolt jam nuts against the axle housings.
7. Tighten the idler wheel cap screws securely.
NOTE: Since track tension and track alignment are
interrelated, always check both even if only one adjustment seems necessary.
! WARNING
If jam nuts are not tightened properly, the adjusting
bolts could loosen causing the track to become
extremely loose and, under some operating conditions, allow the idler wheels to climb over the track
lugs forcing the track against the tunnel causing the
track to “lock.” If a track “locks” during operation,
severe personal injury could result.
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.
727-729A
5. If the distances from the rear idler wheels to the
inner track drive lugs are not the same on both
sides, an adjustment is necessary.
Adjusting
Checking
! WARNING
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. On the side of the track which has the inner track
drive lugs closer to the rear idler wheel, loosen the
idler wheel cap screw and the adjusting bolt jam
nut; then rotate the adjusting bolt clockwise 1 to 1
1/2 turns.
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.
! WARNING
The tips of the skis must be positioned against a wall
or similar object for safety.
0744-947
3. Start the engine and accelerate slightly. Use only
enough throttle to turn the track several revolutions. SHUT ENGINE OFF.
2. Check track alignment and continue adjustment
until proper alignment is obtained.
NOTE: Allow the track to coast to a stop. DO NOT
NOTE: Make sure correct track tension is maintained
apply the brake because it could produce an inaccurate
alignment condition.
after adjusting track alignment (see TRACK TENSION
sub-section).
4. When the track stops rotating, check the relationship of the rear idler wheels and the inner track
drive lugs. If the distance from the rear idler
wheels to the inner track drive lugs is the same on
both sides, no adjustment is necessary.
3. After proper track alignment is obtained, tighten
both the adjusting bolt jam nut and the idler wheel
cap screw securely.
! WARNING
If a jam nut is not tightened properly, the adjusting bolt
could loosen causing the track to become dangerously loose.
4. Field test the track under actual conditions; then
make additional adjustments as necessary.
39
Brake System
REMOVING AND INSPECTING
A998
6. Disconnect the brake cable from the lever; then
slide the brake cable out of the lever.
KEY
1.
2.
3.
4.
5.
6.
7.
Lock Nut
Bushing
Rivet
Chain Tensioner
Spring
Tab
Roller
8.
9.
10.
11.
12.
13.
14.
Washer
Cap Screw
Bracket
Cap Screw
Spacer
Clutch
Brake Band
15.
16.
17.
18.
19.
20.
Retainer Pin
Washer
Retaining Ring
Spacer
Washer
Lock Washer
742-425B
1. Remove the front clutch shield and hood cable.
NOTE: It will be necessary to reinstall the hood cable
once the shield is removed.
2. Loosen the Allen-head retainer pin (A) securing
the brake cable to the brake band; then remove the
retaining ring (B) securing the brake band to the
mounting bracket.
A999
7. Remove the handlebar pad and cut the cable tie
securing the brake cable to the steering post.
NOTE: Note the location of the cable tie for assembly.
8. Inspect the brake band for cracks and/or wear.
NOTE: The brake band pad material thickness must
be at least 1/16" or replacement is necessary.
9. Inspect the brake cable for damage or fraying.
INSTALLING
1. Route the cable through the slot in the brake housing and insert the cable end into the housing.
2. Seat the cable drum into the brake lever recess;
then secure the brake lever with a pin and C-clip.
IO116A
3. Loosen the rear jam nut securing the brake cable to
the brake bracket; then remove the brake cable
from the bracket and brake band. Account for a
spring.
4. Remove the brake band from the engine compartment.
5. Remove the C-clip securing the brake lever pin in
the brake housing; then remove the pin and lever.
A999
40
6. Secure the brake cable to the steering post with a
cable tie; then install the handlebar pad.
7. Install the hood cable and the front clutch shield.
CHECKING BRAKE LEVER TRAVEL
1. Compress the brake lever fully.
2. Check the distance between the brake lever and
the lever stop. The distance must be within a range
of 1/4-1/2".
A998
3. Place the brake band into position on the bracket
and secure with a washer and retaining ring.
0725-565
3. If travel distance is not as specified, adjust the
brake.
ADJUSTING BRAKE LEVER TRAVEL
IO117A
4. Slide the spring onto the brake cable; then insert the
cable end into the brake band. Tighten securely.
735-457A
1. Remove the clutch shield.
A004
5. Secure the brake cable to the bracket with the jam
nuts.
2. Loosen the rearward jam nut on the brake cable;
then tighten the forward jam nut to set up the
brake.
3. Check the brake lever travel distance periodically
while tightening the forward jam nut. When the distance is within the specified range of 1/4-1/2", tighten
the rearward jam nut to secure the adjustment.
4. Install the clutch shield.
A005
41
Troubleshooting Track
Problem: Track Edge Frayed — Drive Lugs Worn
Condition
1. Track alignment adjusted incorrectly
Remedy
1. Align — replace track
Problem: Track Worn Adjacent to Outer Drive Lugs
Condition
1. Track tension adjusted incorrectly
2. Rear idler wheels dirty — damaged
Remedy
1. Adjust track tension
2. Clean — replace idler wheels
Problem: Track Ratchets — Slaps Tunnel
Condition
1. Track tension adjusted incorrectly (too loose)
2. Drive sprockets misaligned — damaged
Remedy
1. Adjust track tension (tighten)
2. Align — replace sprockets
Problem: Wear-Strip Wear Excessive
Condition
1. Slide rail bent — broken — damaged
2. Track alignment adjusted incorrectly
42
Remedy
1. Repair — replace slide rail
2. Adjust track alignment
This section has been organized so each procedure can be
completed individually and efficiently. The technician
should use discretion and sound judgment when removing and installing components.
Rear Suspension
GENERAL INFORMATION
Quick acceleration and the ability to go through the turns
with power are the most important handling qualities.
This section explains how the skid frame functions to
provide these two important handling qualities.
Good weight transfer characteristics are needed for fast acceleration (shift of weight from skis to track) and for cornering
(shift of weight back to skis to hold the front end in turns).
Effective weight transfer depends on suspension tension,
position of rider, and the position of the front arm limiter.
To understand how the suspension system works, think
of the entire system in terms of three points; the skid
frame rear axle center, the skid frame front arm, and the
ski saddle center.
Removing Skid Frame
NOTE: Many service procedures can be performed
without removing the skid frame. Closely observe the
note introducing each subsequent sub-section for this
important information.
1. Loosen the jam nuts and the two track tension
adjusting cap screws.
Assume that the front arm functions as a stationary pivot
point between the rear axle center and the ski saddle center. Also assume that the ski saddle center is the same
height off the ground as the rear axle center. This produces the standard position arrangement.
744-947A
2. Place a support stand under the rear bumper; then
remove the two cap screws securing the upper
idler wheel assembly to the tunnel.
NOTE: The support stand should hold the snowmobile level and not raised off the floor.
0728-180
3. Remove the cap screws securing the front axle,
idler axle, and rear suspension arm to the tunnel.
Under acceleration when the center of gravity is transferred to the rear of the machine, the rear suspension collapses slightly. This brings the rear arm point downward
and with the front arm stationary, the teeter-totter effect
reduces the pressure on the skis, position A.
However, for controlled cornering, more pressure is
needed on the skis. So when the driver decelerates coming into a corner, the center of gravity is transferred forward, putting the required pressure onto the skis and
reducing the pressure on the rear suspension, position C.
This is essentially what weight transfer is all about — the
shift of weight to the rear of the machine for positive
traction and good acceleration or to the front of the
machine for positive handling and cornering control.
REAR ARM SPRING TENSION
The rear spring tension is adjusted for the weight of the
driver. Three possible adjustments exist.
IO115B
4. Remove the support stand; then tip the snowmobile
onto one side using a piece of cardboard to protect
against scratching. Remove the skid frame assembly.
1st block position - light operator
2nd block position - medium operator
3rd block position - heavy operator
43
End Cap
REMOVING
1. Remove the lock nut, washers, and cap screw
securing the end cap.
0743-189
NOTE: A wear strip can be removed and installed
AG297D
2. Using a hammer, tap the end cap off the rail.
CLEANING AND INSPECTING
1. Inspect the end cap area of the slide rail for cracks
and wear.
2. Inspect the end cap for any signs of cracking or
wear.
without removing the skid frame. To do this, remove the
machine screw and lock nut securing the wear strip at
the front of the slide rail; then align the wear strip with
openings (windows) in the track and drive it rearward
off the slide rail. Apply an all-temperature grease to the
new wear strip and slide rail; then align the wear strip
with openings (windows) in the track and drive it forward onto the slide rail. Secure with the machine screw
and lock nut.
1. With the skid frame removed, remove the machine
screw and lock nut securing the wear strip to the
front of the slide rail.
3. Clean both the slide rail area and the end cap. Using
compressed air, clean the areas of dirt and gravel.
! WARNING
Always wear safety glasses when using compressed
air.
4. Inspect the cap screw for cracked, stretched, or damaged threads. Use a new lock nut when assembling.
INSTALLING
1. Position the end cap on the slide rail; then align the
hole in the end cap with the hole in the slide rail.
2. Secure with a cap screws, washers, and new lock
nut. Tighten to 78 in.-lb.
Wear Strip
REMOVING
NOTE: Prior to removing the wear strips, inspect each
wear strip for wear. The wear strip must be 0.42" thick
or thicker. If the wear strip measurement is less than
specified, replacement of both wear strips is necessary.
AG298D
2. Using a pipe wrench and starting from either end,
hook the edge of the wear strip with the pipe
wrench jaw and twist the wear strip off the slide
rail. Move the pipe wrench 3" and again twist the
wear strip off the rail. Repeat this procedure until
the wear strip is free of the rail.
NOTE: The wear strip can also be driven off the slide
rail; however, using a pipe wrench is quicker.
CLEANING AND INSPECTING
1. Clean the slide rail using parts-cleaning solvent
and compressed air.
! WARNING
Always wear safety glasses while using compressed air.
2. Inspect the slide rail for cracks. If any cracks are
found, replace the slide rail.
44
3. Using a straightedge, inspect the slide rail for any
unusual bends. Place the straightedge along the
bottom surface of the slide rail. If the rail is found
to be bent, it must be replaced.
4. Place the straightedge along the side of the slide
rail. If rail is found to be bent, it must be replaced.
INSTALLING
NOTE: Apply a light coat of grease to the slide rail
surface to aid in installing new wear strips. Use a file to
remove any sharp edges on the lower portion of the rail.
AO159
2. Remove the rear springs and sleeves from the rear
arm.
INSPECTING
1. Inspect all rear arm weldments for cracks or
unusual bends.
2. Inspect all tubing for cracks or unusual bends.
3. Inspect the axles for wear or damage.
AG534D
1. Starting from the back, start the wear strip onto the
rail; then using a block of wood and a hammer,
drive the wear strip forward into position.
4. Inspect the upper and lower bearings for wear or
damage.
5. Inspect the two spring adjuster blocks for damage.
6. Inspect the springs for excessive wear, cracks, or
imperfections.
ASSEMBLING
1. Apply a light coat of grease to the axles and the
bushing areas.
2. Place the rear arm into position on the support
bracket and rail; then secure with cap screws
(threads coated with blue Loctite #243). Tighten to
20 ft-lb.
AG535D
Rear Idler Wheels and
Axle
2. Secure with a machine screw and lock nut. Tighten
securely.
Rear Suspension Arm/
Rear Springs
DISASSEMBLING
1. With the skid frame removed, remove the cap
screws securing the rear arm to the support bracket
and rail; then remove the rear arm. Account for
and note the location of all hardware.
744-844A
45
DISASSEMBLING
INSPECTING
1. With the skid frame removed, remove the cap
screws and flat washers securing the outer idler
wheels. Remove the idler wheels from the axle and
account for the adjuster bushings.
1. Inspect each idler wheel for cracks or damage.
2. Slide the axle out of the rear axle housing and the
rear spacer.
3. Inspect the axle and spacers for cracks or bends.
CLEANING AND INSPECTING
2. Rotate the idler wheel bearing (by hand) and
inspect for binding or roughness.
INSTALLING
1. Lightly grease the axle; then slide the inner spacer
onto the axle.
1. Clean the bearings with a clean cloth.
2. Inspect all idler wheel bearings. Rotate each bearing (by hand) and if any roughness or binding is
noted, replace the idler wheel assembly.
2. Place the upper idler wheels into position, place
the spacers into position, and secure with cap
screws (coated with blue Loctite #243). Tighten to
20 ft-lb.
3. Inspect the outer rubber portion of the idler wheels
for cracks and poor bonding.
Slide Rail
4. Inspect the plastic hub of each idler wheel for
cracking.
5. Inspect the axle for wear and damaged threads.
Damaged threads may be repaired with a 3/8 x 16
tap.
ASSEMBLING
1. In order, slide the axle through the rear axle housing; then place a spacer on the axle. Slide the axle
through the opposite axle housing.
2. Place the adjuster bushings on the axle (on the outside of each axle housing). Make sure the adjuster
bushing is positioned properly towards the adjusting cap screw.
744-844A
3. Place the rear idler wheels on the axle and secure
with two cap screws (coated with blue Loctite
#243) and washers. Tighten to 20 ft-lb.
Upper Idler Wheels
REMOVING
1. Remove the two cap screws securing the upper
idler wheels to the tunnel; then remove the wheels.
744-844B
REMOVING
NOTE: When replacing one or both slide rails is necessary, remove one slide rail at a time. The remaining
slide rail will then hold the crossbraces and brackets in
their correct assembly order which is much quicker
than to completely disassemble the entire skid frame.
IO115A
2. Account for and note the location of all spacers.
46
1. With the skid frame removed, remove the cap
screw, washers, and lock nut securing the end cap
to the slide rail. Remove the end cap from the slide
rail.
AG297D
2. Remove the cap screw securing the cross-brace axle
to the slide rail.
AO161
8. Remove the slide rail from the skid frame.
INSPECTING
1. Inspect the slide rail for cracks or unusual bends.
2. Inspect the wear strip for wear. The wear strip
must be 0.42'' thick or thicker. If the wear strip
measurement is less than specified, replacement of
both wear strips is necessary.
AO160
3. Remove the cap screw securing the rear suspension arm to the support bracket.
4. Remove the cap screws and lock nuts securing the
rear suspension arm support bracket.
0743-189
INSTALLING
1. Install the rear axle housing and adjuster bushing;
then secure with cap screws and lock nuts. Tighten
to 20 ft-lb.
2. Install the rear idler wheel and secure the rear idler
wheel with a cap screw (coated with blue Loctite
#243) and washer. Tighten to 20 ft-lb.
AO162
3. Secure the rear suspension arm support bracket to
the slide rail with cap screws and lock nuts.
Tighten securely.
5. Remove the cap screw and washer securing the rear
idler wheel to the axle. Slide the wheel off the axle
and account for the adjuster bushing.
6. Remove the two cap screws and lock nuts securing the rear axle housing; then remove the housing.
7. Remove the push nut and solid rivet securing the
shock pad to the slide rail. Remove the shock pad.
47
AO162
AO161
4. Secure the rear arm to the support bracket with the
cap screw. Tighten securely.
7. Place the end cap onto the rail and secure with the
cap screw, washers, and lock nut. Tighten to 78 in.lb.
Installing Skid Frame
1. Place a piece of cardboard on the floor to protect
against scratching and tip the snowmobile onto
one side.
2. Pull the track away from the tunnel and spread
open; then place the skid frame into the track.
AO159
5. Secure the cross-brace axle to the slide rail with
the cap screw (threads coated with blue Loctite
#243). Tighten to 20 ft-lb.
3. Position the front of the skid frame into the tunnel
and align the front axle with the appropriate
mounting holes in the tunnel. Secure the axle to
the tunnel with the cap screws (coated with blue
Loctite #243). Thread the cap screws in only half
way. DO NOT TIGHTEN AT THIS TIME.
NOTE: To aid in centering the rear arm with the holes
in the tunnel, position the skid frame and track at a 45°
angle to the bottom of the tunnel.
4. Align the rear idler axle with the appropriate
mounting holes in the tunnel. Secure the axle to
the tunnel with the cap screws (coated with blue
Loctite #243). Thread the cap screws in only half
way. DO NOT TIGHTEN AT THIS TIME.
AO160
6. Place the shock pad into position and secure with a
solid rivet and push nut.
5. Align the rear arm with the holes in the arm support bracket. Secure the arm to the bracket with
the cap screws (threads coated with blue Loctite
#243). Tighten to 20 ft-lb.
6. Place the snowmobile in the upright position.
7. Securely tighten all mounting hardware (from
steps 3 and 4) to 20 ft-lb.
8. Check track tension; adjust as necessary (see
Track and Driveshaft section).
48
Steering and Body
Steering Post
REMOVING
NOTE: Perform steps 1-8 for both the brake and throttle cables.
1. Remove the handlebar pad.
A980
2. Remove the C-clips securing the brake and throttle
lever pins in the brake housing and throttle control; then remove the pins and levers.
4. Remove the C-clip securing the throttle cable in
the throttle control; then remove the cable from the
throttle control.
A979
A981
A998
A982
3. Disconnect the brake and throttle cables from the
levers; then slide the cables out of the levers.
5. Cut the cable ties securing the cables to the steering post.
6. Using a sharp knife, cut the grip off the handlebar.
7. Using a solvent, clean the old adhesive from the
handlebar.
8. Loosen the screw securing the emergency stop
switch to the handlebar; then remove the stop
switch.
9. Remove the two cap screws and lock nuts securing
the upper steering post bearing retainer; then
remove the retainer and bearing.
A999
49
INSTALLING
IO059A
10. Pull the steering post up and out of the lower bearing.
11. Remove the lock nuts and cap screws securing the
tie rods to the steering post.
KEY
1.
2.
3.
4.
5.
6.
7.
Steering Post
Handlebar Grip
Throttle Control
Pin
Spring Pin
Decal
Throttle/Brake
Lever
8. Retaining Ring
9. Brake Housing
10. Engine Stop
Switch
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Pad Cover
Pad
Cap Screw
Clamp
Bearing Retainer
Bearing
Lock Nut
Lock Nut
Washer
Cap Screw
Tie Rod
Assembly
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Hex Nut
Hex Nut
Rivet
Support
Tether Switch
Assy
Tether Cord
Brake Cable
Spring
Cable Tie
Throttle Cable
Lock Washer
0746-737
1. Place the lower steering post bearing and retainer
into position on the front end; then loosely secure
with cap screws and lock nuts.
IO060A
NOTE: Use an additional wrench to keep the tie rod
end shaft from turning while removing the tie rod lock
nut.
12. Remove the steering post from the engine compartment.
13. Remove the two cap screws and lock nuts securing
the lower steering post bearing retainer; then
remove the retainer and bearing.
INSPECTING
2. Place the steering post into position in the engine
compartment and secure the inner tie rods to the
steering post with washers and lock nuts (coated
with green Loctite #609). Tighten to 20 ft-lb.
NOTE: Use an additional wrench to keep the tie rod
end shaft from turning while tightening the tie rod lock
nut.
3. Slide the end of the steering post into the lower
steering post bearing and place the upper end of
the steering post on the support.
1. Inspect all welded areas for cracks or deterioration.
2. Inspect the steering post and bearing retainers for
cracks, bends, or wear.
3. Inspect the steering post bearings for wear, cracks,
or deterioration.
4. Inspect the tie rod ends for wear or damage.
A025
4. Place the upper steering post bearing into position
on the steering post and secure the steering post/
bearing assembly to the support with the bearing
retainer, cap screws, and lock nuts.
50
5. Tighten the upper and lower retainer cap screws
securely.
A982
A026
9. Seat each cable drum into its lever recess; then
secure each with a pin and C-clip.
NOTE: Check all fasteners to ensure they are tight.
Turn the handlebar full-left and full-right several times
to ensure free movement.
6. Apply Handlebar Adhesive to the bore of the handlebar grip; then using a rubber hammer, drive the
grip into position.
! WARNING
The handlebar adhesive is extremely flammable. This
product contains acetone. The vapors released can be
easily ignited. Keep away from heat, sparks, and open
flame. Use only in a well ventilated area. Avoid prolonged breathing of vapor. Avoid eye and skin contact.
Keep container closed when not in use.
A980
7. Place the emergency stop switch onto the right
handlebar and secure with the screw.
8. Route the throttle cable through the slot in the
throttle control and insert the cable end into the
throttle control. Secure the cable with a C-clip.
A999
A981
A979
51
REMOVING
Ski
1. Using a suitable stand or lift, raise the front of the
snowmobile off the floor; then remove the lock
nuts securing the wear bar to the ski.
REMOVING
1. Remove the cap screw and lock nut securing the
ski to the spindle.
2. Remove the ski and account for two washers.
INSPECTING
3. Remove the wear bar.
1. Inspect all hardware and spindle axles for any
signs of damage.
2. Inspect the welded areas for cracks or deterioration.
3. Inspect the ski for abnormal bends or cracks.
INSTALLING
KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
2. Pry the rear of the wear bar down until the wear
bar studs are clear of the ski; then slide the wear
bar rearward until the front of the wear bar is free
from the ski.
INSTALLING
1. Insert the front of the wear bar into the hole at the
front of the ski and swing the wear bar upward;
then insert the wear bar studs into the holes in the
ski.
! WARNING
DO NOT bend the ski wear bar excessively when
installing. Excessive bending of the ski wear bar may
cause premature wear, breakage, and possible injury.
Ski
Wear Bar
Lock Nut
Saddle
Lock Nut
Machine Screw
Cap Screw
Washer
Lock Nut
Axle
Spindle
Grease Fitting
Insert
Spindle Cap
Handle
Machine Screw
Washer
Cap Screw
2. Center the wear bar studs in the holes and install
the lock nuts. Tighten lock nuts securely.
Tie Rods
REMOVING AND DISASSEMBLING
1. Remove the tie rod from the spindle.
0747-296
1. Place the ski into position on the spindle; then secure
with a cap screw, two washers, and a lock nut.
CAUTION
Do not over-tighten the ski lock nut or binding will
occur.
2. Tighten the lock nut to 16 ft-lb making sure the ski
is free to pivot.
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. Arctic Cat recommends that the ski
wear bars be checked once a week and replaced if worn
to 1/2 of original diameter.
52
ZJ296A
2. Remove the tie rod from the steering post (see
steps 9-12 of Steering Post - Removing sub-section).
3. Loosen the jam nuts securing the tie rod; then
remove the ball joints from the tie rod. Slide the tie
rod from the steering boot.
CLEANING AND INSPECTING
1. Inspect the ball joints and tie rods for damaged
threads or wear.
2. Inspect the ball joints and tie rods for cracks or
unusual bends.
3. Wash the ball joint in parts-cleaning solvent. Dry
with compressed air. Inspect the ball joint pivot
area for wear. Apply an all-temperature grease to
the ball joint.
3. Remove the lock nut securing the tie-rod ball joint
to the spindle (account for the washer); then
remove the ball joint from the spindle.
! WARNING
Always wear safety glasses when using compressed air.
ASSEMBLING AND INSTALLING
1. Slide the tie rod through the steering boot; then
install the jam nuts and thread the ball joints onto
the tie rod.
NOTE: Each jam nut and ball joint is either a righthand or left-hand thread; therefore, each can only be
installed on one end of the tie rod. The right-hand
thread is the inside ball joint and jam nut.
2. Secure the inner tie rod to the steering post with
washers and lock nuts (coated with green Loctite
#609). Tighten to 20 ft-lb.
ZJ296A
4. Remove the cap screw and lock nut securing the
shock to the spindle. Account for two shock bushings.
3. Secure the steering post to the front end (see steps
3-5 of Steering Post - Installing sub-section).
4. Secure the outer tie rod to the spindle with a
washer and lock nut (coated with green Loctite
#609). Tighten to 15 ft-lb.
IO119A
5. Remove the two cap screws and lock nuts securing
the spindle to the suspension arms. Account for all
mounting hardware.
ZJ296A
NOTE: The ball joint must be installed on the bottom
side of the spindle arm.
5. Lock the jam nuts against the tie rod; then adjust
ski alignment (see Ski Alignment sub-section).
! WARNING
Neglecting to lock the jam nuts against the tie rod may
cause loss of snowmobile control and possible personal injury.
Spindle
REMOVING
1. Position the front of the snowmobile up onto a
safety stand.
2. Remove the ski.
IO119B
6. Inspect the tie-rod ball joint in place. If damage,
wear, or unusual bends are noted, loosen the jam
nut; then remove the ball joint from the tie rod.
INSPECTING
1. Inspect the spindle for excessive wear, cracks,
bends, or imperfections.
2. Inspect all welds for cracking.
53
3. Inspect the suspension arm axle area for wear.
4. Secure the spindle in a vise. Rotate the spindle
clockwise and counterclockwise. The movement
should be smooth and free. If the spindle movement
is rough or binding, grease the spindle with an alltemperature grease. Rotate the spindle. If the movement remains rough, replace the spindle.
NOTE: When greasing the spindle, use enough so it
can be seen coming out at both the top and bottom of
the spindle.
5. Inspect the spindle axle for wear, damage, or loose fit.
INSTALLING
IO119A
4. Install the ski.
1. Place the shock mounting bracket into position on the
spindle; then place the arms into the spindle. Secure
with cap screws and lock nuts. Tighten securely.
5. Remove the safety stand from beneath the front
frame assembly.
Ski Alignment
CHECKING
1. Turn the handlebar to the straight-ahead position.
2. Measure the distances to the inside edges of the
skis in two places. Make sure the measurements
are taken behind the spindle mount and ahead of
the spindle mount.
IO119B
2. Place the tie-rod ball joint into position on the bottom side of the spindle arm and secure with a lock
nut (threads coated with green Loctite #609) tightened to 15 ft-lb.
0735-446
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 1/4" toe out
(front measurement 1/4" more than rear measurement).
ZJ296A
3. Place the lower shock eyelet w/shock bushings
into the shock mounting bracket. Secure with the
cap screw and lock nut. Tighten to 20 ft-lb.
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
1. Make sure the ignition key is in the OFF position.
2. Visually examine the skis to determine which ski
is out of alignment with respect to the handlebar.
3. Open the hood and loosen the jam nut on each end
of the tie rod.
54
4. While holding the straight ski in position, rotate
the tie rod until the measurement between the skis
is 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 the tie rod.
! WARNING
Neglecting to lock the tie rod by tightening the jam
nuts may cause loss of snowmobile control and possible personal injury.
Front Suspension A-Arms
A033
NOTE: If the cap screw must be removed, it will be
necessary to remove the belly pan (see Belly Pan subsection).
REMOVING
1. Position the front of the snowmobile up onto a
safety stand.
2. Remove the spindle (see Spindle sub-section).
INSPECTING
1. Inspect the A-arm welded areas for cracks or any
signs of deterioration.
NOTE: The ski does not have to be removed from the
2. Inspect the axles for wear or damage.
spindle for this procedure.
3. Inspect the tubing for signs of being twisted or bent.
3. Remove the cap screw and lock nut securing the
upper shock eyelet to the upper A-arm; then remove
the shock. Account for two shock bushings.
INSTALLING
KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Upper A-Arm
Lower A-Arm
Axle
Axle
Axle
Cap Screw
Cap Screw
Lock Nut
Shock Mounting Bracket
Washer
0741-771
AO167
4. Remove the lock nuts securing the A-arms to the chassis; then push the cap screws as far forward as possible.
1. Slide the A-arms onto the cap screws and swing
them up into position on the front end; then secure
with lock nuts. Tighten to 30 ft-lb.
2. Install the spindle (see Spindle sub-section).
Front Suspension (Ski)
Shock Absorber
REMOVING
1. Position the front of the snowmobile up onto a
safety stand taking all pressure off the skis.
AO169A
5. Angle the rear of each A-arm downward and slide
them off the cap screws. Account for two outer
axles and an inner axle for each arm.
2. Remove the cap screws securing the shock
absorber to the front end assembly and spindle;
then remove the shock absorber. Account for all
mounting hardware.
55
3. Using the Shock Spring Removal Tool, remove
the spring from the shock body by compressing
the spring; then remove the spring retainer from
the top of the spring. Inspect the shock absorber by
quickly compressing and extending the shock
plunger while firmly holding the shock body.
Resistance must be felt in both directions.
CLEANING AND INSPECTING
1. Inspect the shock absorber seal area for signs of
excessive oil leakage.
2. Inspect the shock absorber mounting eyelet, bushings, and body for wear or damage.
INSTALLING
1. Using the shock spring tool, place the spring on
the shock absorber and secure with the retainer.
A040
4. Using a piece of cardboard to protect the finish, tip
the snowmobile on the right side and using a #20
drill bit, drill out the belly pan rivets.
2. Install the bushings, sleeves, and spacers into each
shock end; then place the shock absorber into position. Install both cap screws from the front.
Tighten the lock nuts to 20 ft-lb.
Belly Pan
REMOVING
1. Remove the hood.
2. Remove the two cap screws securing the belly pan
to the front end; then account for washers and lock
washers.
AL174D
NOTE: The tie rod boots do not need to be removed.
5. Using a piece of cardboard to protect the finish, tip
the snowmobile on the left side and using a #20
drill bit, drill out the belly pan rivets.
6. With all belly pan rivets removed, return the snowmobile to the upright position; then slide the belly
pan forward and up until it clears the front end.
INSPECTING
1. Inspect for gouges, cuts, and tears.
2. Inspect the two belly pan threaded bosses and
ensure they are in good shape.
A039A
3. Remove the two Phillips-head screws securing the
belly pan to the footrest supports.
INSTALLING
1. Slide the belly pan into position on the front end;
then secure with cap screws, lock washers, and
washers (forward) and Phillips-head screws (rearward).
2. Install the three belly pan rivets in each ski-well.
3. Using a piece of cardboard to protect the finish, tip
the snowmobile on its side and install the remaining belly pan rivets; then return the snowmobile to
the upright position.
4. Install the hood.
56
Seat/Cushion/Taillight
Housing
7. Remove the vent hose from the top of the gas tank.
A044
8. Raise the flap at the rear of the seat and remove the
two cap nuts securing the seat assembly to the tunnel. Account for two washers.
KEY
1. Seat Assy
2. Gas Tank/Seat-Base
3. Cap w/Gauge
4. Seal
5. Seat Cover
6. Seat Wire
7. Foam
8. Seat Wire
9. Staple
10. Clip
11. Vent Hose
12. Bushing
13. Push Nut
14. Decal
15. Teflon Tape
16. Shut-Off Valve
17. Hose Clamp
18. Fuel Hose
19. Fuel Filter
20. Hose Clamp
21. Fuel Hose
22. Hose Clamp
23. Cable Tie
24. Spring
25. Choke Cable
26. Nut
27. Decal
28. Ignition Switch
29. Retaining Nut
30. Ignition Switch Key
31. Cap Screw
32. Lock Nut
33. Washer
34. Cap Nut
35. Taillight Assy
36. Washer
37. Nut w/Washer
9. Raise the rear of the seat assembly high enough to
disconnect the taillight wiring harness; then disconnect the taillight from the main wiring harness.
10. Remove the seat assembly.
NOTE: If necessary, use a sharp tool to pry out all staples securing the seat cover to the plastic seat base;
then remove the cover from the seat base and seat
foam.
INSTALLING
0747-299
REMOVING
1. Remove the retaining nut securing the ignition
switch to the console; then slide the switch forward and out of the console.
2. Remove the screw securing the choke knob to the
cable; then remove the knob.
3. Remove the two nuts securing the choke cable to
the console; then slide the cable forward and out of
the console.
NOTE: If the seat cover was removed, position the
cover over the seat foam and plastic seat base. Check
to make sure it is positioned straight; then fold the rear
edge of the cushion down and around the base. Using a
staple gun and 1/4-in. staples, staple the rear flap of the
cushion to the base in the same areas as the original
staples were located. Position staples 1" apart. Fold the
sides of the cushion down around the bottom edge of
the base. Position the staples in the same areas as the
original staples were located.
1. Place the seat assembly into position and connect
the taillight wiring harness.
4. Pull the recoil starter rope out approximately 24";
then tie a slip-knot in the starter rope below the
console and allow the rope to slowly retract
against the starter case.
2. Secure the seat assembly to the tunnel with washers and cap nuts.
5. Remove the knot at the handle and remove the
handle; then thread the rope through the bushing in
the console.
4. Thread the recoil starter rope through the bushing in
the console and the handle; then tie a knot at the end
of the rope and pull the handle up and onto the knot.
6. Turn the gas tank shut-off valve to the CLOSED
position; then disconnect the fuel hose from the
carburetor.
5. Untie the slip-knot at the starter case and allow it
to slowly rewind into the case.
! WARNING
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.
3. Connect the vent hose to the top of the gas tank.
6. Slide the choke cable through the console and
secure with two lock nuts; then using a screw
(coated with blue Loctite #243), secure the choke
knob to the end of the cable.
7. Slide the ignition switch into position on the console; then secure with the retaining nut.
57
8. Connect the fuel hose to the carburetor and turn
the gas tank shut-off valve to the OPEN position.
Headlight Assembly
REMOVING
 NOTE: The bulb portion of the headlight is fragile.
HANDLE WITH CARE. When replacing the headlight
bulb, the bulb assembly must first be removed from the
housing. Do not touch the glass portion of the bulb. If
the glass is touched, it must be cleaned with a dry cloth
before installing.
1. Peel back the rubber headlight socket cap; then
push in and turn the headlight socket counterclockwise and remove it from the headlight housing.
2. Remove the caps covering the four headlight
adjustment screws; then remove the adjustment
screws. Remove the headlight from the hood.
IO120A
INSTALLING
1. Secure the headlight housing to the hood with the
four adjustment screws; then snap the caps on the
screws.
NOTE: The hood cable is secured with the lower righthand adjustment screw.
2. Insert the headlight bulb socket into the headlight
housing; then rotate the socket clockwise to lock it
into the housing.
3. Place the rubber headlight socket cap over the
headlight housing bead around the socket.
NOTE: To adjust headlight aim, adjust the four adjustment screws until maximum illumination for the operator is apparent.
58
Wiring Diagram
0744-204
59
NOTES
60
Printed in U.S.A.
Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-960