OPERATOR’S MANUAL - Arctic Cat · OPERATOR’S MANUAL ZR 5000/7000/9000 ... The law of the State of ... This Operator’s Manual should be considered a permanent part of the snowmobile

O P E R A T O R ’ S M A N U A L

www.arcticcat.com

ZR 5000/7000/9000XF 7000/9000M 7000/9000

Limited Warranty Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on eachnew Arctic Cat Snowmobile it assembles and on each genuine Arctic Cat Snowmobile part and accessoryassembled and sold by an authorized Arctic Cat Snowmobile dealer. The limited warranty on an Arctic CatSnowmobile is extended to the original retail purchaser for the time periods described below; however, thebalance of the remaining warranty may be transferred to another party unless the purchase is forcommercial use (see below). Warranty coverage is only available in the country in which the original retailpurchase occurs to the original retail purchaser resident in that country or to a transferee resident in thatcountry of the balance of the remaining warranty.

Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products willfunction properly when used with an Arctic Cat Snowmobile or will not damage the Arctic Cat Snowmobile.Arctic Cat does not assume any liability for incidental or consequential damages.

Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any partsthat are found to be warrantable in material or workmanship. This repair work MUST be done by anauthorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costswill be paid by Arctic Cat. The warranty is validated upon examination of said parts by Arctic Cat or anauthorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such parts at its factory forfinal determination if warranty should apply.The warranty periods are as follows:

1. For snowmobiles used for recreational purposes:—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR from December 1of the current year.—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.

2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from thedate of invoice and/or 5000 MILES whichever comes first (non-transferable).

3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditionswithout proper lubrication or additional idler wheels), and the following parts:

Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured UpholsteryWear Bars Brake Pads Spark Plugs Drive Clutch/Driven Clutch Wear PartsWear Strips Shock Absorber(s) - Standard* Shock Absorber(s) - Rebuildable*** Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock,

corroded or pitted shaft, peeling chrome.** Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted)

- replace for defective shock, corroded or pitted shaft, peeling chrome.The following will VOID Arctic Cat’s warranty:

1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (ifstored for extended periods), and/or service as recommended in the Operator’s Manual.

2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer.3. Use of an improper fuel mixture ratio.4. Use of improper carburetor jets.5. Use of improper gasoline, lubricating oils, or spark plugs.6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.7. Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.8. Use of the snowmobile in any way for racing purposes.9. Removal of the engine for use in another vehicle.

10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.11. Use of parts not sold or approved by Arctic Cat.12. Track and tunnel damage resulting from either ice stud or hooker plate installation.13. Damage due to improper transportation.

Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic, punitive,consequential and incidental damages, lost profits, and loss of use. Some states or provinces do not allowthe exclusion or limitation of incidental or consequential damages, so the above limitation may not apply toyou. Arctic Cat’s aggregate liability may not exceed the price of the product. The law of the State ofMinnesota shall apply to all claims or disputes, exclusive of its conflicts of law provisions.

IMPLIED WARRANTY EXCLUSION AND DISCLAIMERTo the fullest extent permitted by law, Arctic Cat excludes and disclaims all implied warranties ofmerchantability and fitness for a particular purpose.

If you are not satisfied with warranty service or repairs, you should contact Arctic Cat at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.

Table of ContentsLimited Warranty .....................Inside Front CoverForeword ............................................................1Declaration of Conformity...................................2Snowmobile Safety Rules ..................................3General Information ......................................4-21Snowmobile Identification.................................. 4Control Locations .............................................. 4Gasoline-Oil....................................................... 5Engine Break-In................................................. 6Drive Belt Break-In ............................................ 6Cold Drive-Away Function ................................. 6Speedometer/Tachometer/Indicator Icons......... 7Diagnostic Codes ............................................ 12Handlebar Height/Tilt (M/XF)........................... 12Handlebar Tilt (ZR/XF) .................................... 13Speedometer/Tachometer Angle (5000/9000) 14Exhaust System .............................................. 14Air-Intake Silencer ........................................... 14Cooling System ............................................... 14Battery ............................................................. 14Jump-Starting .................................................. 15Drive Clutch and Driven Clutch ....................... 16Drive Clutch/Driven Clutch Alignment ............. 16Fuel Pump ....................................................... 16Shock Absorbers (Rebuildable Gas) ............... 16Standard Track (XF/ZR)................................... 17Paddle Track (XF High Country/M).................. 17Track Studs (XF/ZR) ........................................ 17Reverse Operation .......................................... 18Access Panel/Hood (Removing/Installing) ...... 20Removable Seat (ZR/XF) ................................ 21Towing ............................................................. 21

Operating Instructions .................................22-25Starting and Stopping Engine ......................... 22Braking ............................................................ 23Emergency Stopping ....................................... 24

Throttle/Ignition Monitor Switch .......................24Varying Altitude Operation...............................25

Lubrication.................................................. 26-27Chain Case......................................................26Rear Suspension .............................................27

Maintenance............................................... 28-50Periodic Maintenance Checklist.......................28Air Cleaner/Filter (9000) ..................................29Fuel System.....................................................29Checking Engine Oil Level...............................30Changing Engine Oil/Filter...............................31Coolant Level...................................................32Spark Plugs .....................................................33Checking/Adjusting Valve Clearance...............34Battery .............................................................34Fuses...............................................................37Brake System ..................................................37Burnishing Brake Pads ....................................40Drive Belt .........................................................41Track Tension...................................................43Track Alignment ...............................................44Suspension......................................................45Lights ...............................................................48Ski Wear Bars..................................................49Adjusting Ski Stance........................................50Rail Wear Strips...............................................50

Performance Tips ....................................... 51-52Preparation for Storage .............................. 53-53Preparation after Storage .................................54U.S. EPA Emission Control Statement/

Warranty Coverage (U.S. Only).....................55Change of Address, Ownership, or Warranty

Transfer .........................................................57Warranty Procedure/Owner

Responsibility .......................Inside Back Cover

Reference InformationWrite the appropriate information for your Arctic Cat Snowmobile in the spacesbelow.

Always use these numbers when referring to your snowmobile.

Model: _________________________________________________Date of Purchase: ________________________________________Vehicle Identification Number: _______________________________Engine Serial Number: _____________________________________Your Arctic Cat Dealer: ___________________________________Address: _______________________________________________Phone: _________________________________________________

! WARNINGA snowmobile is a very high performance vehicle. Because it does acceleraterapidly and is capable of very high speeds, it should not be operated by a nov-ice or an inexperienced operator. Never accelerate rapidly or drive at high speedbeyond the limits of visibility or without being totally familiar with the terrainand what lies in front of you. Obey speed limits and never operate at speedsthat do not allow adequate maneuvering and stopping distances. Read andstudy the entire Operator’s Manual and Safety Handbook.Failure to follow this warning could result in personal injury to yourself or others.

Personal Injury• To avoid injury to yourself and others, NEVER operate the snowmobile without

first reading and understanding this manual and the Snowmobile Safety Hand-book; then follow the instructions and heed the warnings given.

• USE COMMON SENSE.• DON’T DRINK and DRIVE.• STAY IN CONTROL at ALL TIMES.• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at

excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it istoo late to warn of the consequences of snowmobile misuse. Such conductendangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-SELF AND OTHERS.

Parts and AccessoriesWhen in need of replacement parts, oil, or accessories for your Arctic Cat Snowmo-bile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSO-RIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet thestandards and requirements of your Arctic Cat Snowmobile. For a complete list ofaccessories, refer to the current Arctic Cat Accessory Catalog. To aid in service andmaintenance procedures on these snowmobiles, an Illustrated Parts Manual and aService Manual are available through your local Arctic Cat Snowmobile dealer.

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ForewordCongratulations! You have chosen a quality Arctic Cat Snowmobile designed andassembled to give dependable service. Be sure, as the owner/operator of an ArcticCat Snowmobile, to become thoroughly familiar with its basic operation, mainte-nance, and off-season storage procedures. Read this manual and the accompanyingSnowmobile Safety Handbook before operating the snowmobile to learn safe andproper use of your new Arctic Cat Snowmobile. Always operate the snowmobilewithin your level of skill and current terrain conditions.

The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decalsdisplay the words Warning, Caution, and Note to emphasize important information.The symbol ! WARNING identifies personal safety-related information. Besure to follow the directive because it deals with the possibility of serious personalinjury or even death. A CAUTION identifies unsafe practices which may resultin snowmobile-related damage. Follow the directive because it deals with the possi-bility of damaging part or parts of the snowmobile. The symbol NOTE: identi-fies supplementary information worthy of particular attention.

This manual covers operator-related maintenance, operating instructions, and off-season storage instructions. If major repair or service is ever required, contact anauthorized Arctic Cat Snowmobile dealer for professional service.

At the time of publication, all information and illustrations were technically cor-rect. Some illustrations used in this manual are used for clarity purposes only andare not designed to depict actual conditions. Because Arctic Cat Inc. constantlyrefines and improves its products, no retroactive obligation is incurred.

This Operator’s Manual should be considered a permanent part of the snowmobileand must remain with the snowmobile at the time of resale. If the snowmobilechanges ownership more than once, contact Arctic Cat Inc., Service Department,P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.This manual was prepared by the Product Service and Warranty Department ofArctic Cat Inc.

Every Arctic Cat Snowmobile meets or exceeds the standards of the SnowmobileSafety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.endorses and encourages the safe use of all snowmobiles. Always wear a helmetand eye protection. Drive with caution, observe all state and local regulations, andrespect the rights of others. ISMA members like Arctic Cat do their part to improvetrails, sponsor events, and generally support the sport of snowmobiling. As a mem-ber of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmobil-ing through education, charity, and research programs.

© 2014 Arctic Cat Inc.

Printed in U.S.A.

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Declaration of Conformity

I, the undersigned, hereby declare that the equipment specified above conforms to thedirective(s) and standard(s) as specified.

Brad DarlingVice President/General Manager - Snowmobile Division

Application of council directives:Issued by European Commission.

EMC Directive 2004/108/ECEC Machinery Directive 2006/42/EC

Type of Equipment: SnowmobileModel Numbers:

Brand Name: Arctic Cat

S2015M6DE3OSG S2015X7UHIUSO S2015XFULEOSO S2015ZRNSPUSOS2015M7USPOSG S2015X9NCTOSO S2015XFULEUSG S2015ZRNTROSGS2015M7USPUSG S2015X9NCTUSO S2015XFULEUSO S2015ZRNTRUSGS2015M9NHCOSG S2015X9NHCOSO S2015XFULXUSG S2015ZRNTSUSGS2015M9NHCUSG S2015X9NHCUSO S2015XFUSPOSG S2015ZRUEEOSGS2015M9NLEOSG S2015X9NLEUSO S2015XFUSPOSO S2015ZRUEEUSGS2015M9NLEOSO S2015XFNLEOSO S2015XFUSPUSG S2015ZRULEOSOS2015M9NLEUSG S2015XFNLEUSG S2015XFUSPUSO S2015ZRULEUSOS2015M9NLEUSO S2015XFNLEUSO S2015ZRNEEOSG S2015ZRULXUSGS2015X6DCTOSO S2015XFNLEUSO S2015ZRNEEUSG S2015ZRURROSGS2015X6DHIOSO S2015XFNSPUSG S2015ZRNLEOSO S2015ZRURRUSGS2015X7UCCOSO S2015XFNSPUSO S2015ZRNLEUSO S2015ZRUSPOSGS2015X7UCCUSO S2015XFNTSUSG S2015ZRNLXUSG S2015ZRUSPUSGS2015X7UCTOSO S2015XFULEOSG S2015ZRNSPUSG S2015ZRUSPUSOS2015X7UCTUSOS2015X7UHIOSO

Standards to which conformity is declared:EMC: EN 55012, EN 61000-6-2 MACHINERY: EN 12100:2010Manufacturer (if not issuing agent): Arctic Cat Inc.

601 Brooks Ave. S.Thief River Falls, MN 56701 USA

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Snowmobile Safety Rules

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General InformationSnowmobile IdentificationThe Arctic Cat Snowmobile has two impor-tant identification numbers. The VehicleIdentification Number (VIN) is stampedinto the tunnel near the right-side footrestand on a decal beneath the seat. The decal(located on the tunnel) also displays perti-nent production information. The EngineSerial Number (ESN) is stamped into thecrankcase of the engine.

0726-383

These numbers are required by the dealerto complete warranty claims properly. Nowarranty will be allowed by Arctic CatInc. if the engine serial number or VIN isremoved or mutilated in any way.

Always provide the snowmobile name,VIN, and ESN when contacting an autho-rized Arctic Cat Snowmobile dealer forparts, service, accessories, or warranty. Ifthe complete engine must be replaced,ask the dealer to notify Arctic Cat forcorrect registration information.

Control LocationsShown are the typical control locationsfor Arctic Cat snowmobiles. Location ofa specific control will vary according tomodel.

XF/M

0748-261

ZR

0748-260

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RR

0746-789

Gasoline-OilRecommended Gasoline (5000/7000)

The recommended gasoline to use inthese snowmobiles is 87 octane regularunleaded. In many areas, oxygenates areadded to the gasoline. Oxygenated gaso-lines containing up to 10% ethanol areacceptable gasolines.

When using ethanol blended gasoline, it isnot necessary to add a gasoline antifreezesince ethanol will prevent the accumula-tion of moisture in the fuel system.

Recommended Gasoline (9000)

The only recommended gasoline to use inthese snowmobiles is 91 octane (minimum).

NOTE: For optimum performance,use only 91 octane (minimum) gasoline.

In many areas, oxygenates are added to thegasoline. Oxygenated gasolines containingup to 10% ethanol are acceptable gasoline.Do not use gasolines containing methanol.

Recommended Engine Oil

The recommended oil to use is C-TEC4Synthetic Oil (p/n 6639-524 - qt) or (p/n6639-528 - gal.).

After the engine break-in period, theengine oil should be changed every 2500miles (5000/7000) or 2000 miles (9000)and before prolonged storage.

Filling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled toits rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area.

Also, if the snowmobile is to remain on atrailer after filling the gas tank, the bed ofthe trailer must be maintained level toprevent gasoline from draining outthrough the gas tank vent hose.

CAUTIONDo not use white gas or gasolinescontaining methanol. Only Arctic Catapproved gasoline additives shouldbe used.

CAUTIONIf a situation arises wherein 91 octanegasoline is not available, 89 or 87octane gasoline can be substituted;however, do not prolong the usage of89 or 87 octane gasoline as it willcause poor engine performance.

CAUTIONDo not use white gas or gasoline con-taining methanol. Only Arctic Catapproved gasoline additives shouldbe used.

! WARNINGAlways fill the gas tank in a well-venti-lated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running. DONOT SMOKE while filling the gas tank.Do not sit on the snowmobile withoutfirst installing the gas tank cap.

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Engine Break-InThe Arctic Cat engine (when new or rebuilt)requires a short break-in period before theengine is subjected to heavy load conditions.

7000

Premixing fuel and oil during the breakin period is not required.

There is never a more important period inthe life of the engine than the first 300 miles.

Since the engine is brand new, do not putan excessive load on it for the first 300miles. The various parts in the enginewear and polish themselves to the correctoperating clearances. During this period,prolonged full throttle operation or anycondition that might result in engineoverheating must be avoided.

Operating your snowmobile for the firsttime: Start the engine and let it idle for 15minutes.

0-160 km (0–100 miles): Avoid pro-longed operation above 6000 RPM.

160-500 km (100–300 miles): Avoid pro-longed operation above 8000 RPM.

500 km (300 miles) and beyond: The snow-mobile can now be operated normally.

NOTE: After 500 miles of opera-tion, the engine oil must be changedand the oil filter replaced. If anyengine trouble should occur duringthe engine break-in period, immedi-ately have a Arctic Cat dealer checkthe snowmobile.

5000/9000

This engine does not require any pre-mixed fuel during the break-in period.

To ensure trouble-free operation, carefuladherence to the following break-inguidelines will be beneficial.

* With occasional full-throttle operation.

To ensure proper engine break-in, ArcticCat recommends that the engine oil andfilter be changed after 500 miles. Thisservice is at the discretion and expense ofthe snowmobile owner.

Drive Belt Break-InDrive belts require a break-in period ofapproximately 25 miles. Drive the snow-mobile for 25 miles at 3/4 throttle or less.By revving the engine up and down (butnot exceeding 60 mph), the exposed cordon the side of a new belt will be worndown. This will allow the drive belt togain its optimum flexibility and willextend drive belt life.

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt.

Cold Drive-Away FunctionOn these models, there is a “cold drive-away” function incorporated within theECM.

When cold-starting the engine, the cool-ant temperature warning icon will illumi-nate and the TEMP (5000/9000) or LOWTEMP (7000) display on the readoutscreen will begin to flash. With theengine in this temperature range, theRPM “limit” of the engine will be belowdrive system engagement speed. As theengine warms, the coolant temperaturewarning icon will begin to flash, theTEMP (5000/9000) or LOW TEMP(7000) display will continue to flash, andthe RPM “limit” of the engine willincrease allowing the snowmobile tomove without full-throttle operation.When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and the TEMP (5000/9000)or LOW TEMP (7000) display will goout.

CAUTIONDO NOT use premixed fuel in thesnowmobile gas tank. Engine dam-age will occur.

0-200 miles 1/2 Throttle (45 MPH-max)200-400 miles 1/2-3/4 Throttle400-600 miles 1/2-3/4 Throttle *

CAUTIONNever run the engine with the drivebelt removed. Excessive revving of theengine could result in serious enginedamage and drive clutch failure.

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Speedometer/Tachometer/Indicator IconsThese snowmobiles are equipped withdifferent gauge styles. Determine whichstyle your model is equipped with anduse the appropriate following informa-tion.

Standard Gauge (5000/9000)

Certain models are equipped with a stan-dard gauge combination speedometer/tachometer. Indicator icons are incorpo-rated within the speedometer/tachome-ter. Also incorporated into thespeedometer/tachometer is a digital read-out screen.

FZ003C

RPM/MPH (kph)

By pushing the left button once, the RPMand MPH will be displayed (one on thereadout screen and one with the needle).By pushing the button once again, thefunctions will be reversed.

By pushing the left button (with speedbeing displayed) for more than two sec-onds, the display will change betweenstandard mph or metric kph. Release thebutton when desired display appears.

With RPM displayed on the readoutscreen by pushing and holding the leftbutton, maximum RPM will be displayedon the readout screen. The maximumRPM readout will reset when the rightbutton is pushed (while maximum RPMis displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter/Clock

By pushing the right button, the readoutscreen will display odometer, trip-meter(1), trip-meter (2), hour-meter, and clock.To reset the trip meter with the trip meterdisplayed, push and hold the right buttonuntil the display is cleared. The hour-meter readout will not reset.

Clock

With the clock selected on the readoutscreen by pushing and holding the rightbutton for two seconds, the option ofselecting the 12-hour or 24-hour clock isavailable. Push the left button for 12-hourdisplay; push the right button for 24-hourdisplay. At this point, the hours and min-utes will begin to flash. Push the left but-ton to change the hour display; push theright button to change the minute display(either tap the buttons for individual num-ber display or push and hold the buttonsfor rapid number display).

NOTE: During clock setting if nei-ther button (left, right) is pushedwithin a 5-second time period, theclock-setting mode will be exitedwith changes saved.

A. Oil Pressure Warning Icon

This icon indicates engine oil pressure,not the oil level; however, if the oil levelis low, it may affect oil pressure.

CAUTIONOn the 5000/9000, it is extremelyimportant that the engine is properlywarmed up before subjecting theengine to high speed operation orheavy loads. The engine should beallowed to idle at least 3-4 minutesbefore it is operated at more than 1/2throttle. In extremely cold conditions,the warm-up time will be longer. Coldseizure and piston scuffing causedby insufficient warm-up will not becovered by warranty. Also, do not idlethe engine for excessively long peri-ods of time.

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The icon should illuminate each time theignition switch is turned to RUN orSTART, and it should go out when theengine starts. If the icon illuminateswhile the engine is running, oil pressurehas been lost and the engine will auto-matically shut off.

If oil pressure is lost, check the oil level(see page 30).

If the warning icon does not go out or ifthe engine does not start, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

B. Coolant Temperature Warning Icon

NOTE: When cold-starting theengine, the coolant temperature warn-ing icon will illuminate, the readoutscreen will display TEMP, and engineRPM limit will be below drive systemengagement speed.

When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and TEMP display willcease to flash.

If the coolant temperature rises too far aboveproper operating temperature, the coolanttemperature warning icon will flash a warn-ing (alert) and the engine will “surge” toalert the operator. If the coolant temperaturerises to a critical point above proper operat-ing temperature, the coolant temperaturewarning icon will cease flashing and willremain constantly illuminated.

NOTE: If the coolant temperatureicon is constantly on, the engine willshut off if vehicle speed is reducedto 1.5 kph (0.9 MPH) or slower.

C. Low Fuel Indicator

The indicator illuminates whenever the gas in the gas tank is low.

D. Fuel Level Display

This bar display shows the approximateamount of gas remaining in the gas tank.

E. Service Icon

The icon should illuminate each time the key is turned to RUN or START, and it should go out when the engine starts. If the icon stays illuminated or it illuminates while the engine is running, the system is receiving input that is outside of its established parameters. If the icon illuminates indicating an error, take the snowmobile to an authorized Arctic Cat Snowmobile dealer for service. If not under warranty, this service is at the discretion and expense of the snowmobile owner.

F. High Beam Indicator

The indicator is on whenever the highbeam mode is selected by the headlightswitch.

G. Charging System Warning Icon

This icon is designed to warn the operatorif the battery charging system is not func-tioning. The icon should illuminate eachtime the key is turned to RUN or START,and it should go out when the enginestarts. If the icon stays illuminated or itilluminates while the engine is running,the battery is not being charged, and thesnowmobile is running on battery reservepower only.

If the Charging System Warning Iconilluminates, you should, as soon as possi-ble, take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner. The engine WILLNOT RUN without battery power.

CAUTIONAt this point, take precautionary mea-sures such as changing to loose snowterrain, shutting the engine off (allow-ing the engine to cool down), andchecking coolant level. If unable toeither determine or remedy the prob-lem, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

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Deluxe Gauge (5000/9000)

Certain models are equipped with a deluxegauge combination speedometer/tachome-ter. Indicator icons are incorporated withinthe speedometer/tachometer. Also incorpo-rated into the speedometer/tachometer is adigital readout screen.

FZ001F

RPM/MPH (kph)

By pushing the increment button once,the RPM and MPH will be displayed(one on the readout screen and one withthe needle). By pushing the button onceagain, the functions will be reversed.

By pushing the increment button (withspeed being displayed) for more than twoseconds, the display will change betweenstandard mph or metric kph.

With RPM displayed on the readoutscreen by pushing and holding the incre-ment button, maximum RPM will be dis-played on the readout screen. Themaximum RPM readout will reset whenthe decrement button is pushed (whilemaximum RPM is displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter

By pushing the decrement button, thereadout screen will display odometer,trip-meter (1), trip-meter (2), and hour-meter. To reset the trip meter with the tripmeter displayed, push and hold the decre-ment button until the display is cleared.The hour-meter readout will not reset.

Clock/Altimeter

By pushing the select button, the readoutscreen will display clock, altimeter, andmaximum altimeter.

To set the clock, select clock on the displayby pushing and holding the select buttonfor two seconds; the option of selecting the12-hour or 24-hour clock mode is avail-able. Push the increment button to togglebetween the 12-hour display and the 24-hour display. When desired mode is dis-played, push the select button.

At this point, the hours display will beginto flash. Push the increment button toincrease the hours; push the decrementbutton to decrease the hours. Pushing andholding a button will accelerate the num-ber display. When desired hour number isdisplayed, push the select button.

At this point, the minutes display willbegin to flash. Push the increment buttonto increase the minutes; push the decre-ment button to decrease the minutes.Pushing and holding a button will accel-erate the number display. When desiredminute number is displayed, push theselect button.

NOTE: During clock setting if nobutton (increment, decrement,select) is pushed within a 5-secondtime period, the clock-setting modewill be exited with changes saved.

NOTE: The altimeter readout isbased off barometric pressure andmay require calibration as weatherconditions change.

To set/calibrate the altimeter to an estab-lished altitude with altimeter selected onthe display screen by pushing and hold-ing the select button for a minimum oftwo seconds, the acronym CAL will bedisplayed on the readout screen for onesecond; then the altitude value will flash.Push the increment button to increase thedisplayed altitude; push the decrementbutton to decrease the displayed altitude.Pushing and holding a button will accel-erate the number display.

NOTE: If MPH has been selected inthe speed readout, the altitude valuewill be displayed in feet. If kph hasbeen selected in the speed readout,the altitude value will be displayed inmeters.

10

To reset the maximum altimeter readoutwith the maximum altimeter displayed,push and hold the select button for a min-imum of two seconds.

A. High Beam Indicator


B. Oil Pressure Warning Icon

This icon indicates engine oil pressure,not the oil level; however, if the oil levelis low, it may affect oil pressure.

The icon should illuminate each time theignition switch is turned to RUN or START,and it should go out when the engine starts.If the icon illuminates while the engine isrunning, oil pressure has been lost and theengine will automatically shut off.

If oil pressure is lost, check the oil level(see page 30).

If the warning icon does not go out or ifthe engine does not start, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

C. Coolant Temperature Warning Icon

NOTE: When cold-starting theengine, the coolant temperaturewarning icon will illuminate, thereadout screen will display TEMP,and engine RPM limit will be belowdrive system engagement speed.

When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and TEMP display willcease to flash.

If the coolant temperature rises too farabove proper operating temperature, thecoolant temperature warning icon willflash a warning (alert) and the engine will“surge” to alert the operator. If the coolanttemperature rises to a critical point aboveproper operating temperature, the coolanttemperature warning icon will cease flash-ing and will remain constantly illumi-nated.

NOTE: If the coolant temperatureicon is constantly on, the engine willshut off if vehicle speed is reducedto 1.5 kph (0.9 MPH) or slower.

D. Service Icon

The icon should briefly illuminate eachtime the key is turned to RUN or START,and engine is started; then it should goout when the engine starts. If the iconstays illuminated or it illuminates whilethe engine is running, the system isreceiving input that is outside of its estab-lished parameters. If the icon illuminatesindicating an error, take the snowmobileto an authorized Arctic Cat Snowmobiledealer for service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

E. Charging System Warning Icon

The Charging System Warning Icon isdesigned to warn the operator if the batterycharging system is not functioning. Theicon should illuminate each time the key isturned to RUN or START, and it should goout when the engine starts. If the icon staysilluminated or it illuminates while theengine is running, the battery is not beingcharged, and the snowmobile is running onbattery reserve power only.

If the Charging System Warning Iconilluminates, you should, as soon as possi-ble, take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner. The engine WILLNOT RUN without battery power.

CAUTIONAt this point, take precautionary mea-sures such as changing to loose snowterrain, shutting the engine off (allow-ing the engine to cool down), andchecking coolant level. If unable toeither determine or remedy the prob-lem, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

11

Deluxe Digital Gauge (7000)

CWI-051A

A. Coolant Temperature Indicator

The indicator and LOW TEMP display willcease to flash when the engine reachesproper operating temperature.

If the coolant temperature rises too farabove proper operating temperature, theindicator will flash a warning (alert) andthe engine will “surge” to alert the opera-tor. If the coolant temperature rises to acritical point above proper operating tem-perature, the indicator will cease flashingand will remain constantly illuminated.

NOTE: If the indicator is constantlyon, the engine will shut off if vehiclespeed is reduced to 1.5 km-h (0.9MPH) or slower.

B. High Beam Indicator


C. Oil Pressure

The indicator relates to engine oil pres-sure, not the oil level; however, if the oillevel is low, it may affect oil pressure. Ifoil pressure is lost, check the oil level(see page 30).

If the indicator does not go out or if theengine does not start, take the snowmo-bile to an authorized Arctic Cat Snowmo-bile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

D. Low Fuel Indicator

The indicator illuminates whenever thegas in the gas tank is low.

E. Coolant Temperature/Battery Voltage/Intake Air Temperature Display

This bar display shows coolant tempera-ture, battery voltage, and intake air tem-perature. Press the Lower Left Button tochange which parameter is being dis-played. Press and hold the Lower LeftButton to see the actual values associatedwith the mode selected.

F. Fuel Level Display

This bar display shows the approximateamount of gas remaining in the gas tank.

G. RPM/Speed/Clock/Altimeter

Press the Upper Left Button to cycle theleft screen between RPM and speed.

NOTE: When RPM is displayed onthe left screen, the right screen willdisplay speed, clock, or altimeter.When speed is displayed on the leftscreen, the right screen will displayRPM, clock or altimeter.

Press the Upper Right Button to cycle theright screen between speed, RPM, clock,and altimeter.

Press and hold the Upper Button on thespeed-side of the gauge to shift betweenstandard (MPH/miles/Fahrenheit) andmetric (km/h/kilometers/Celsius).

Press and hold the Upper Button on theRPM-side to view maximum RPM. Thisvalue is reset each time the ignition key isturned off.

CAUTIONIf the indicator is illuminated, stop theengine immediately and allow it to cooldown. If unable to either determine orremedy the problem, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

12

With the clock mode selected by pressingthe Upper Right Button, press and hold theUpper Right Button to set the clock. Theoption of selecting the 12-hour or 24-hourclock is available; press the either Left But-ton to alternate between the two modes.Next, press the Lower Right Button to setthe clock. Press either Left Button to set thehours; then press the Lower Right Button toset the minutes. Press either Left Button toset the minutes. When the proper time hasbeen set, press the Lower Right Button toreturn to the main gauge display.

With the altimeter mode selected bypressing the Upper Right Button, pressand hold the Upper Right Button to setthe current altitude by using either LeftButton. When the proper altitude hasbeen set, press the Lower Right Button toreturn to the main gauge display.

H. Engine Hour Meter/Odometer/Trip Meter/Clock

This display shows engine hours, odome-ter, trip meter, or clock. Press the LowerRight Button to change which parameteris being displayed. The Engine HourMeter and Odometer cannot be reset. Toreset the trip meter, select the Trip Meter;then press and hold the Lower Right But-ton until the trip meter display reads 0.

NOTE: The clock can only be dis-played in this position if it is notalready being displayed in the mainright screen. To set the clock whenthe clock is in this position, pressand hold the Lower Right Button;then use the procedure found in G.

Diagnostic CodesDiagnostic codes are activated by theECM and may be displayed on the read-out screen for a number of reasons.

If a code is displayed while the engine isrunning, the ECM is receiving input thatis outside of its established parameters. Ifa code has been activated, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.

Refer to the following chart for diagnos-tic codes.

5000/9000

* 9000

7000

Code Trouble1 Failure in the fuel system.2 Failure in injector (PTO).3 Failure in injector (MAG).4 Failure in barometric pressure sensor.5 Open or short circuit in intake mani-

fold air temperature sensor.6 Open or short circuit in water temper-

ature sensor.7 Open or short circuit in throttle posi-

tion sensor.8 Open or short circuit in manifold air

pressure sensor.9 Failure in crankshaft position sensor.

11 Failure in speed sensor.12 Failure in coil (MAG).13 Failure in coil (PTO).14 Failure in ISC valve.15 Failure in oxygen sensor.19 Failure in camshaft position sensor.21* Open or short circuit in/or loose knock

sensor.22* Failure in injector (PTO secondary).23* Failure in injector (MAG secondary).25 Failure in shifting system/gear position

switch.26 Malfunction in air pressure sensor.29 Malfunction in shift control switch.

OCTN* Low octane gasoline.

Code TroubleP0031 O2 Heater Control Circuit LowP0032 O2 Heater Control Circuit HighP0107 Manifold absolute pressure circuit lowP0108 Manifold absolute pressure circuit highP0112 Intake air temp sensor circuit lowP0113 Intake air temp sensor circuit highP0115 Engine coolant temp sensor 1 circuitP0117 Engine coolant temp sensor 1 circuit

lowP0118 Engine coolant temp sensor 1 circuit

highP0120 Throttle position sensor circuitP0122 Throttle position sensor circuit lowP0123 Throttle position sensor circuit highP0130 O2 sensor circuitP0131 O2 sensor circuit lowP0132 O2 sensor circuit highP0171 System too leanP0172 System too rich

13

Handlebar Height/Tilt (M/XF)To adjust handlebar height, use the fol-lowing procedure:

1. From each side of the steering post,compress the locking tabs to unlockthe handlebar.

0747-618

2. With the tabs compressed, adjust thehandlebar up or down to the desiredposition; then release the tabs to lockthe handlebar in place.

NOTE: When the desired height isfound, make sure that the lock collaris seated in the grooves by lifting upand pressing down on the handlebar.

To adjust handlebar tilt, use the followingprocedure:

1. Loosen the four cap screws and tiltthe handlebar to the desired position.

0747-617

2. Tighten the four cap screws evenlyto 15 ft-lb.

Handlebar Tilt (ZR/XF)The handlebar can be adjusted to theoperator’s preference. To adjust the han-dlebar, use the following procedure:

1. Remove the handlebar cover; thenloosen the eight cap screws securingthe handlebar caps to the riser and theriser to the steering post.

P0201 Injector circuit/open - cylinder 1P0202 Injector circuit/open - cylinder 2P0203 Injector circuit/open - cylinder 3P0217 Engine coolant over temp conditionP0261 Cylinder 1 injector circuit lowP0264 Cylinder 2 injector circuit lowP0267 Cylinder 3 injector circuit lowP0508 Idle air control system circuit lowP0509 Idle air control system circuit highP0511 Idle air control circuitP0522 Engine oil pressure sensor circuit lowP0523 Engine oil pressure sensor circuit highP0562 System voltage lowP0563 System voltage highP0780 Shift ErrorP1315 Crankshaft Position out of syncP1338 Crankshaft spike detectedP1339 Crankshaft tooth not detectedP1685 Main relay open circuitP1686 Main relay circuit lowP1688 Reverse relay open circuitP1689 Reverse relay circuit lowP1691 Forward relay open circuitP1692 Forward relay circuit lowP1694 Headlight relay open circuitP1695 Headlight relay circuit lowP2228 Barometric pressure sensor A circuit

lowP2229 Barometric pressure sensor A circuit

highP2300 Ignition coil A primary control circuit

lowP2303 Ignition coil B primary control circuit

lowP2306 Ignition coil C primary control circuit

lowU1000 Vehicle not registered or invalid PINU1001 Vehicle not registered and vehicle lim-

its enabledU0155 Lost communication with the ECM

Code Trouble

! WARNINGTighten the cap screws according tospecifications to prevent unexpected“movement” of the handlebar duringoperation over rough terrain. DO NOTposition handlebar so steering (maxi-mum right/left turning capabilities) orthrottle and brake controls are affected.

14

0745-848

2. Adjust the handlebar to operator’sdesired position, tighten the capscrews evenly to 15 ft-lb, and checksteering for maximum right/leftturning capabilities.

NOTE: Do not rotate the handlebarto a position that allows air to enterthe brake system.

Speedometer/Tachometer Angle (5000/9000)The speedometer/tachometer can beadjusted to the operator’s desired position.To adjust, use the following procedure.

1. Loosen the lock nuts and cap screwson each side of the speedometer/tachometer bracket.

2. Adjust the speedometer/tachometerto the desired angle; then tighten thelock nuts securely.

Exhaust SystemThe exhaust system is designed to reducenoise and to improve the total perfor-mance of the engine. If any exhaust sys-tem component is removed from theengine and the engine is run, severeengine damage will result.

Air-Intake SilencerUsed in conjunction with the fuel intakesystem is a specially designed air-intakesilencer. The purpose of the silencer is toquiet the intake of fresh air. Since the fuelintake system is calibrated with the air-intake silencer in place, the engine mustnever be run with the silencer removed.Performance will not be improved if theair-intake silencer is removed. In con-trast, severe engine damage will occur.

Cooling SystemThese snowmobiles are equipped with aclosed liquid cooling system for enginecooling. The cooling system should beinspected daily for leakage and damage.Also, the coolant level should be checkeddaily. If leakage or damage is detected,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

When filling the cooling system reser-voir, use an ethylene glycol-based cool-ant/water mixture which will satisfy thecoldest anticipated weather conditions ofyour area in accordance with the coolantmanufacturer’s recommendations.

NOTE: If operating on ice or hard-packed snow conditions, it is recom-mended that Ice Scratchers (p/n 5639-897) be installed and engaged toreduce wear strip wear and engineoverheating.

For checking/filling cooling system, refer toCoolant Level sub-section in the Mainte-nance section.

Battery

It is extremely important that the battery bemaintained at full charge at all times andthat the battery connections be clean andtight. If charging the battery becomes neces-sary, refer to Battery sub-section in theMaintenance section.

! WARNINGTighten cap screws according tospecifications to prevent unexpected“movement” of the handlebar duringoperation over rough terrain. DO NOTposition the handlebar so steering(maximum right/left turning capabili-ties) or throttle and brake controlsare affected.

CAUTIONThese snowmobiles are not designedto be operated in dusty conditions.Operating the snowmobile in dustyconditions will result in severeengine damage.

15

Jump-Starting

NOTE: Arctic Cat does not recom-mend jump-starting a snowmobilewith a dead battery but rather toremove the battery, service it, andcorrectly charge it; however, in anemergency, it may be necessary tojump-start a snowmobile. If so, usethe following procedure to carefullyand safely complete this procedure.

NOTE: To access the battery, theseat must be removed.

1. On the snowmobile to be jump-started,slide any terminal boots away.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, orbulging sides. Leaking or bulgingbattery cases may indicate a frozenor shorted battery.

3. Inspect the vehicle to be used forjump-starting to determine if voltageand ground polarity are compatible.The vehicle must have a 12-volt DC,negative ground electrical system.

4. Move the vehicle to be used for thejump-start close enough to ensurethe jumper cables easily reach; thenset and lock the brakes, shut off allelectrical accessories, and turn theignition switch OFF.

NOTE: Make sure all switches onthe snowmobile to be jump-startedare turned OFF.

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive(red) cable to the positive (+) termi-nal (1) of the dead battery (C) beingcareful not to touch any metal withthe other clamp; then attach theother clamp of the positive (red)cable to the positive (+) terminal (2)of the good battery (B).

0744-527

NOTE: Some jumper cables may bethe same color but the clamps or endswill be color-coded red and black.

CAUTIONAlways turn the ignition switch key tothe OFF position when the snowmo-bile is not being used. Leaving theignition switch in the ON position willresult in discharging the battery andpossible damage to the battery.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns,or blindness as a result of an explo-sion. Always remove rings andwatches. Any time service is per-formed on a battery, the followingmust be observed: keep sparks, openflame, cigarettes, or any other flameaway. Always wear safety glasses.Protect skin and clothing when han-dling a battery. When servicing a bat-tery in an enclosed space, keep thearea well-ventilated

! WARNINGIf any of these conditions exist, DONOT attempt to jump-start, boost, orcharge the battery. An explosioncould occur causing serious injury.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electri-cal damage may occur.

CAUTIONFailure to disconnect electronicaccessories during jump-startingmay cause system damage due topower spikes.

16

7. Attach one clamp of the negativejumper cable (black) to the negative(-) terminal (3) of the good battery(B); then attach the other clamp ofthe negative (black) jumper cable (4)to an unpainted metal surface (A) onthe engine or frame well away fromthe dead battery and fuel systemcomponents.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle torun for several minutes applyingsome charge to the dead battery.

9. Start the snowmobile with the deadbattery and allow it to run for severalminutes before disconnecting thejumper cables.

10. Remove the jumper cables in oppo-site order of hook-up (4, 3, 2, 1). Becareful not to short cables againstbare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the snowmobile again.

Drive Clutch and Driven ClutchThe drive clutch and driven clutch do notrequire lubrication; therefore, no specialmaintenance is required by the snowmo-bile owner except for periodical cleaning.

However, the drive clutch and drivenclutch should be disassembled, cleaned,and inspected by an authorized ArcticCat Snowmobile dealer after every 800miles of operation or at the end of thesnowmobiling season whichever occursfirst. This service is at the discretion andexpense of the snowmobile owner.

When operating the snowmobile at highaltitudes, it may be necessary to changecertain component parts of the driveclutch and/or the driven clutch. See anauthorized Arctic Cat Snowmobile dealerfor further information.

Drive Clutch/Driven Clutch AlignmentThe alignment between the drive clutch anddriven clutch is set at the factory. Normally,no adjustment is necessary as long as neitherthe drive clutch nor the driven clutch isremoved or disassembled. However, if pre-mature drive belt wear is experienced or ifthe drive belt turns over, the drive clutch/driven clutch alignment must be checked.Take the snowmobile to an authorized Arc-tic Cat Snowmobile dealer for this service.If not under warranty, this service is at thediscretion and expense of the snowmobileowner.

Fuel PumpThe fuel pump is designed to provideadequate amount of gas to the injectorsat all throttle settings. If a fuel deliveryproblem is suspected, take the snowmo-bile to an authorized Arctic Cat Snowmo-bile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

Shock Absorbers (Rebuildable Gas)Each shock absorber should be visiblychecked weekly for fluid leakage, cracksor breaks in the body/reservoir, or a bentshaft. If any one of these conditions isdetected, replacement or service is neces-sary. Take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forthis service. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

NOTE: When the snowmobile isoperated in extremely cold weather (-23° C/-10° F or colder), a smallamount of leakage may be present.Unless the leakage is excessive,replacement is not necessary.

! WARNINGNever make the final connection to abattery as a spark could ignite hydro-gen gases causing an explosion ofthe battery resulting in acid burns orblindness.

CAUTIONDO NOT attempt to service the driveclutch and driven clutch. The driveclutch and driven clutch must be ser-viced by an authorized Arctic CatSnowmobile dealer only.

17

NOTE: The frequency of servicingrebuildable shock absorbers willvary according to the types of condi-tions and terrain the snowmobile hasbeen subjected to. If riding qualitydeteriorates (or seems to be deterio-rating), take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for shock absorber evaluationand/or servicing. This service is atthe discretion and expense of thesnowmobile owner.

Kits are available to either stiffen orsoften gas shock valving.

Standard Track (XF/ZR)Accelerated wear strip and track clipwear caused by operating on ice or hard-packed snow conditions is NOT coveredunder Arctic Cat Inc. warranty policy.

NOTE: If regularly operating on iceor hard-packed snow conditions,Performance Wear Strips (p/n 6639-448) may be installed at the expenseof the snowmobile owner.

Paddle Track (XF High Country/M)These models are equipped with a PowerClaw style track which is speciallydesigned for use in powder snow ridingconditions. When the Power Claw track isoperated in hard-packed snow conditions,it will run slightly slower than a standardtrack and it will accelerate wear strip wear.To decrease the amount of wear strip wear,slower speeds must be maintained whenoperating on hard-packed trails. Acceler-ated wear strip wear caused by operating aPower Claw track on hard-packed snowconditions is NOT covered under ArcticCat Inc. warranty policy.

NOTE: If operating on ice or hard-packed snow conditions, it is recom-mended that Ice Scratchers (p/n 5639-897) be installed to reduce wear stripwear and engine overheating.

Track Studs (XF/ZR) NOTE: Stud or hooker plate installa-tion will void track and tunnel warranty.

NOTE: Arctic Cat does not recom-mend studding a track with greaterthan a 1.6 inch lug.

NOTE: Stud installation can be per-formed by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

NOTE: All 7000 models are manu-factured with tunnel protectors.

For proper installation, use the followingprocedure:

1. Using the appropriate stud template(see chart), mark the desired studpattern to be used.

2. Using the proper-sized stud holedrill bit, drill out the stud holes.

3. Push the stud through the hole frominside the track; then place thedomed support plate and lock nut onthe exposed stud.

4. Using a wrench to secure the stud,tighten the lock nut on the exposed stud.

! WARNINGWhen installing studs on a single-plytrack, it is important to use ArcticCat-approved studs (proper headdiameter). If approved studs (properhead diameter) are not used, studscould tear free of the track causingpossible injury or even death. Con-sult an authorized Arctic Cat Snow-mobile dealer for information.

CAUTIONTo prevent tunnel damage from thestuds, Tunnel Protector Kit (p/n 6639-075) for the ZR, (p/n 6639-118) for theXF, or (p/n 6639-207) for HCR must beinstalled.

Stud Template ChartTrack Length p/n

129 in. 6639-461137 in. 6639-462141 in. 4639-991

18

It is also recommended that wheneverstuds are installed on a track, carbidewear bars should be installed on the skis.Carbide wear bars complement the trackstuds to balance steering control underthese conditions. The length of the car-bide on the wear bars should be propor-tionate to the number of track studs (i.e.small number of track studs — shortlength of carbide...many track studs —long length of carbide). The proper pro-portion between the number of studs andcarbide length on the wear bar will main-tain steering balance.

Reverse OperationThe engine reverse function offers theoperator the convenience of being able toback up the snowmobile rather than hav-ing to turn the snowmobile around byhand. This feature, under most situations,should not be used to free a stuck snow-mobile as it will tend to dig the skisdeeper into the snow. Always use mini-mal speed when operating in reverse andcome to a complete stop before shiftingfrom either forward to reverse or reverseto forward.

5000/9000

741-438A

NOTE: Correct drive belt tension(deflection) is important for thereverse function to operate properly.If the belt is too tight, difficulty inengaging reverse will be experi-enced (the reverse function willmake up to three attempts to engageinto reverse, and if the function isnot completed after the thirdattempt, the engine will shut down).

NOTE: Always warm up the enginefor 2-3 minutes prior to shifting intoreverse. The reverse function is can-celled when engine temperature isbelow or above normal operatingrange.

1. To shift into reverse, stop the snow-mobile and allow the engine to idle(under 3000 RPM); then press andrelease the reverse button. Thereverse selection will be complete.

NOTE: Shift only with the engine atidle RPM and the snowmobile com-pletely stopped. The reverse func-tion will not engage if engine isabove 3000 RPM. If attempting toshift into reverse at too high engineRPM (above 3000 RPM), the reversefunction will be cancelled and thecoolant temperature warning iconwill flash. This indicates the reverseswitch button was pressed at toohigh RPM. The operator must reduceengine RPM below 3000 and pressthe button a second time.

2. Upon pressing the reverse switchbutton, the reverse function willmake up to three attempts to engageinto reverse. If the function is notcompleted after the third attempt,the engine will shut down.

! WARNINGAlways balance the snowmobile withthe proper proportion between thenumber of studs and carbide lengthon the wear bars. Do not “over drive”conditions; use common sense in alloperating conditions.

CAUTIONDo not use studs that are more than9.525 mm (0.375 in.) longer than thetrack lug height.

! WARNINGDo not operate a snowmobile withloose studs as they may be thrownfrom the track. Always use a shieldedsafety stand whenever performingany maintenance or adjustments.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

19

NOTE: When reverse is engaged, areverse icon will illuminate in thespeedometer/tachometer and areverse alarm will sound.

NOTE: If the throttle lever is com-pressed before complete reverseengagement, the engine may shutdown. Always wait for the reverseicon to illuminate and the reversealarm to sound before backing up.

3. The system will not shift until the but-ton is released. Also, the reverse func-tion will cancel if operated in reverselonger than 45 seconds. Whenever thereverse function has been cancelled,the engine must be run in the forwardmode for a minimum of 60 seconds at2000 RPM before the reverse func-tion can be used again.

NOTE: While operating in reverse, a“rev-limiter” will activate at 6500 RPM.

4. To shift into forward, stop the snow-mobile and allow the engine to idle(under 3000 RPM); then press thereverse button and release. The for-ward selection will be complete.

5. After shifting from reverse to forward(or from forward to reverse), applythe throttle slowly and evenly to allowthe driven clutch to engage properly.

6. The reverse function is cancelledwhenever the engine is shut off.

7000

741-438A

1. To shift into reverse, stop the snow-mobile and allow the engine to idle(under 2000 RPM); then press andrelease the reverse button. Thereverse selection will be complete.

NOTE: Shift only with the engine atidle RPM and the snowmobile com-pletely stopped. The reverse func-tion will not engage if engine isabove 2000 RPM.

NOTE: When reverse is engaged, areverse icon will illuminate in thespeedometer/tachometer and areverse alarm will sound.

NOTE: Always wait for the reverseicon to illuminate and the reversealarm to sound before backing up.

CAUTIONNever shift into reverse while thesnowmobile is moving forward as it ishard on the driven clutch torquebracket and the cam rollers.

! WARNINGDo not use high speed when backingup. Control could be lost and injurycould occur.

CAUTIONDo not use high speed when backingup. Damage to the drive belt anddriven clutch components may occur.

CAUTIONAfter reversing in deep powder snowconditions, make sure the snowflapdoes not become “caught up” in thetrack. Track and/or snowflap damagemay occur.

CAUTIONIf the snowmobile is equipped withice scratchers, the scratchers mustbe disengaged or component dam-age will occur.

CAUTIONNever shift into reverse while thesnowmobile is moving forward as it ishard on the sprockets.

20

2. The system will not shift until thebutton is released.

3. To shift into forward, stop the snow-mobile and allow the engine to idle(under 2000 RPM); then press thereverse button and release. The for-ward selection will be complete.

4. After shifting from reverse to forward(or from forward to reverse), applythe throttle slowly and evenly to allowthe sprockets to engage properly.

5. The reverse function is cancelledwhenever the engine is shut off.

Access Panel/Hood (Removing/Installing)To remove the access panel and hood, usethe following procedure:

1. Remove the hairpin clip from the pinlocated at the front of the accesspanel. On the M/XF, remove thethumb screw securing the front leftaccess panel to the front facia.

0746-800

2. Move the panel up and off the pin;then swing the panel all the way outand unhinge the panel from thelower console.

3. Remove the torx-head screws secur-ing the hood (located on the under-side of the hood above the front tubeof the upper A-arm); then removethe two torx-head screws from thetop-side of the hood securing thehood to the upper console and thetwo torx-head screws from under thenosepiece of the hood.

0746-792

0747-529

0746-091

4. Remove the intake panel below thegauge; then locate the hood harnessconnector (located in front of thespeedometer) and unplug the con-nector; then move the hood slightlyforward and remove the hood.

! WARNINGDo not use high speed when backingup. Control could be lost and injurycould occur.

CAUTIONAfter reversing in deep powder snowconditions, make sure the snowflapdoes not become “caught up” in thetrack. Track and/or snowflap damagemay occur.

CAUTIONIf the snowmobile is equipped withice scratchers, the scratchers mustbe disengaged or component dam-age will occur.

5000

7000

9000

21

NOTE: On the 9000, first unhook therubber straps securing the air filterhousing to the intake plenum of thehood; then move the hood slightly for-ward and remove the hood.

To install the access panel and hood, usethe following procedure:

1. Position the hood onto the snowmo-bile and connect the hood harnessconnector making sure the harnessdoes not become pinched and themounting screw clips are in position.

NOTE: On the 9000 prior to securingthe hood, make sure the air filter isseated properly into the air silencer andsecured using the two rubber straps.

2. Secure the hood with torx-headscrews and tighten securely.

NOTE: On the 5000, make sure thefoam seal is in place on the air intake.

NOTE: On the 9000, make sure theair filter housing is properly con-nected and secured with the rubberstraps to the intake plenum of thehood and turbocharger.

3. Install the access panel onto the lowerconsole; then close the access paneland secure with the hairpin clip andthumb screw. Install the intake panel.

Removable Seat (ZR/XF)These snowmobiles are equipped with aremovable seat. To remove the seat removethe screw from the underside of the seat;then lift on the back of the seat and move itup and rearward to remove it.

746-088A

To install the seat, route the front tab onthe seat through the seat-base hold-downbracket; then install the seat and secureusing the cap screw.

SNO-273

NOTE: On the LXR prior to lower-ing and securing the seat, connectthe seat heater harness connector.

TowingIf the snowmobile is to be towed byanother snowmobile, do not tow usingthe loops in the skis. The tow rope shouldbe attached to the spindles.

CAUTIONOn the LXR prior to removing the seat,lift the rear of the seat and disconnectthe seat heater harness connector.

22

Operating InstructionsStarting and Stopping EngineIt is imperative that the brake system bechecked for wear and proper operationand that all safety checks found in theaccompanying Snowmobile SafetyHandbook be performed before attempt-ing to start the engine. After the enginehas been started, check the headlights(high and low beam), taillight, and brake-light to be sure they are working properlyand adjusted correctly. Make sure alllights are clean to provide maximum illu-mination. The headlight and taillightmust be clean and must be illuminatedwhenever the engine is running.

1. Test the operation of the brake systemby compressing the brake lever. Thebrake lever must feel firm when com-pressed; then while holding the brakelever in the compressed position, mea-sure the distance between the brakelever and the handlebar. The distancemust be greater than 2.54 cm (1 in.).

0745-816

2. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. Thebrake fluid level must be at the highbrake fluid mark in the reservoir.

0745-817

3. If the brake fluid is below the highbrake fluid mark, add Arctic Catapproved DOT 4 brake fluid untilthe fluid is at the recommendedlevel. Install and secure the reservoircover. Do not allow moisture to con-taminate the brake system.

4. Test the throttle control lever bycompletely compressing and releas-ing it several times. The leverMUST return to the idle positionquickly and completely.

5. Move the emergency stop switch tothe UP or RUN position.

6. Insert key into ignition switch; thenrotate key to the RUN position.

7. Rotate the key to the START posi-tion; then when the engine starts,release the key.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Arctic Catapproved brake fluid.

! WARNINGDo not start the engine if the brake sys-tem is not functioning properly. Servicethe brake system or have it properlyrepaired prior to operating the snow-mobile. Serious personal injury or evendeath may occur if the brake system isnot operating properly.

CAUTIONAlways check the coolant level beforestarting the engine.

CAUTIONDo not continuously run the starterfor more than 5 seconds at a time.

23

NOTE: When the engine starts,allow it to warm up properly. Idle theengine several minutes until theengine has reached normal operat-ing temperature. Do not idle theengine for excessively long periodsof time.

NOTE: There is a “cold drive-away” function incorporated withinthe ECM. This function is active untilthe engine reaches operating tem-perature.

8. Flooding — If the engine does notstart but seems ready to start, engagethe brake lever lock; then compressthe throttle control lever fully andtry to start the engine. When theengine starts, release the throttlecontrol lever immediately. After thewarm-up, release the brake leverlock.

9. To shut off the engine, turn the igni-tion key to the OFF position or pushthe emergency stop switch to theDOWN position.

BrakingThe following items are items that theoperator must be familiar with whenoperating this snowmobile and itshydraulic brake system. Important addi-tional information on the proper mainte-nance of the brake system is found in theMaintenance section.

1. Use the brakes wisely. Each time thebrakes are applied in all hydraulicbrake systems (including automotiveapplications), heat is transferred to thebrake fluid. The amount of heat trans-ferred during high speed stops and/orrepetitive use may be high enough toboil the brake fluid and cause thebrakes to either fade or may cause anunexpected loss of brakes.

If this occurs, the brake fluid requiresa cool-down period before the brakeswill again function properly. Thiscool-down period will vary dependingupon the ambient air temperature andthe temperature of the brake fluid. Ifloss of brakes has occurred because ofhigh fluid temperatures, do not oper-ate the snowmobile until the cool-down period has expired and brakelever firmness has returned.

2. Be sure to maintain the brake fluid atthe proper level and take care not toget any moisture in the system asmoisture in the brake fluid lowers theboiling point. If the brake fluid is everboiled (by high speed stops or repeti-tive use) or if moisture is allowed toenter the system, it must be changed.Never substitute or mix different typesor grades of brake fluid.

3. Never ride the brake. Even main-taining minimal pressure on thebrake lever will cause the brake padsto drag on the disc and may overheatthe brake fluid.

4. The brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes.NEVER OPERATE THE SNOW-MOBILE WITH THE BRAKELEVER LOCK ENGAGED.

CAUTIONAlways turn the ignition switch key tothe OFF position when the snowmo-bile is not being used. Leaving theignition switch in the ON position willresult in discharging the battery andpossible damage to the battery.

! WARNINGExcessive, repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wear beforeeach use. Brake loss can result insevere injury or even death.

24

5. Pumping the brake lever is permissible;however, if pumping the brake levermore than twice is necessary to obtainthe necessary stopping power, immedi-ately take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

6. When new brake pads are installed,a “burnishing” process is required.

Emergency StoppingThere are several methods of stopping orslowing the snowmobile under a varietyof situations. Identified in the followingchart are the ways a snowmobile may bebrought to a stop and the effectivenessunder normal conditions.

Throttle/Ignition Monitor SwitchThe throttle control is equipped with amonitor switch for safety purposes whichwill stop the engine when a loss of returnspring force occurs. If ice forms in thethrottle system or if there is some othermalfunction of the throttle system result-ing in a loss of return spring force, themonitor switch will stop the engine whenthe throttle control lever is released.

If the snowmobile engine stops abruptlywhen the throttle control lever is releasedand the activation of the monitor switch issuspected, use the following procedure:

1. Rotate the ignition key to the OFFposition.

2. Remove ice and snow from thethrottle system and wait 5-10 min-utes for the engine heat to thaw icefrom the throttle system.

3. Test the throttle control lever bycompressing and releasing it severaltimes. The lever MUST return to theidle position quickly and completely.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, compress the throttlelever slightly (approximately 1/8throttle) and try starting the engine.If the engine now starts and stopswhen the throttle lever is released,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

4. If the throttle control lever operatesproperly, rotate the ignition key tothe RUN position and go throughnormal starting procedures.

! WARNINGThe brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes. Thebrake lever lock maintains the brakelever in the compressed position andmaintains pressure against the brakedisc; however, after a period of time,the pressure applied to the brake discmay relax below the amount requiredto hold the snowmobile stationary.

Item FunctionEmergency Stop

Switchinterrupts ignition circuit

Throttle/Ignition Monitor Switch

interrupts ignition circuit

Ignition Switch interrupts ignition circuit

Brake slows the drive system

Tether (HCR/RR) interrupts ignition circuit

! WARNINGIf any malfunction of the throttle sys-tem occurs (such as freezing in fluffysnow) and the monitor switch doesnot shut off the engine, press downon the emergency stop switch IMME-DIATELY to stop the engine. DO NOTstart the engine until the malfunctionin the throttle system has beenlocated and corrected.

! WARNINGIf the throttle control lever does notwork properly, DO NOT ATTEMPT TOSTART THE ENGINE.

25

NOTE: If the throttle control leveroperates properly and the enginedoes not start, a malfunctioning moni-tor switch may be the problem. Takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for service.If not under warranty, this service is atthe discretion and expense of thesnowmobile owner. However, if a direemergency exists wherein the enginemust be started, disconnect the throt-tle monitor switch located in the right-side handlebar control.

NOTE: If disconnection of the throt-tle monitor switch is needed to startthe engine, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service as soon as possi-ble. If not under warranty, this serviceis at the discretion and expense of thesnowmobile owner.

NOTE: The monitor switch is nowbypassed. All other ignition/electri-cal features (ignition switch, emer-gency stop switch, headlight,taillight, and brakelight) will operateproperly.

Varying Altitude OperationOperating a snowmobile at varying alti-tudes requires changes in performancecomponents. These changes affect drivetrain components (on certain models).

For altitude information, see the appro-priate specifications sheet.

NOTE: Just as important as cali-brating the snowmobile for higher alti-tudes is recalibrating the snowmobilewhen going to lower altitudes.

XF models are initially set up at the fac-tory for operation between 0-3000 feet.

ZR models are initially set up at the fac-tory for operation between 0-5000 feet.

M models are initially set up at the fac-tory for operation between 6000-9000feet.

NOTE: Drive train changes can bemade by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

! WARNINGUnder no circumstances should dis-connection of the throttle control wir-ing harness be used as a substitutefor the monitor switch during normaloperation of the snowmobile. Per-sonal injury and damage could occurif the throttle system malfunctions orif the operator is unable to stop theengine in an emergency. If the snow-mobile must be operated with a dis-connected throttle control wiringharness, EXTREME CAUTION MUSTBE TAKEN. NEVER EXCEED 10 MPHWITH THE THROTTLE CONTROLWIRING HARNESS DISCONNECTED.

26

LubricationChain CaseNOTE: The snowmobile must beon a level surface for this procedure.

1. Check the lubricant level in thechain case by using the sight glass.

0746-115

NOTE: The correct level is whenthe lubricant is at least halfway up inthe sight glass.

NOTE: Adding lubricant can bedone by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

2. If the lube level is low, remove thethree screws securing the shift actua-tor to the chain case, disconnect theactuator wiring harness, and removethe actuator w/extension; then addappropriate amount of Arctic CatSynthetic Chain Lube (p/n 6639-539) through the shift actuator open-ing. When the lube is halfway up thesight glass, install the shift actuatorw/extension and connect the actua-tor wiring harness. Tighten screws to36 in.-lb.

0748-259

3. Start the engine and verify properreverse and forward operation by shift-ing in and out of reverse three times.

NOTE: If excessive build-up ofmoisture or discolored oil isdetected in the chain case, it may benecessary to replace the lube.

NOTE: Replacing the lubricant canbe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

To replace the lubricant, use the follow-ing procedure:

NOTE: The side panels, hood, andexhaust resonator must be removedfor this procedure.

1. Place a drain pan under the chaincase; then loosen the eleven screwssecuring the chain case cover/oil tankassembly to the chain case housingstarting with the bottom screws first.

NOTE: It is critical that the snow-mobile is on a level surface toensure the lubricant drains properlyand completely.

NOTE: Inspect the chain casecover seal for nicks or damage.

2. When the lubricant has completelydrained from the case and the chaincase is cleaned of old oil; then installthe chain case cover. Tighten the capscrews to 12-14 ft-lb.

CAUTIONWhen installing the shift actuator,rotate the actuator back and forth toproperly align it with the extensiongear. Failure to do so could causecomponent damage.

CAUTIONBefore installing the chain casescrews, be sure to clean the holesusing compressed air completely ofdebris or damage to the chain casemay occur.

27

XM092

3. Remove the three screws securingthe shift actuator to the chain case,disconnect the actuator wiring har-ness, and remove the actuator w/extension. Pour recommended chainlube through the shift actuator open-ing until the lubricant is at least half-way up in the sight glass; then installthe shift actuator w/extension andconnect the actuator wiring harness.

NOTE: Make sure the reverse sen-sor wire is routed up so the wires donot become pinched between theactuator and the case.

XM014A

4. Install and secure the exhaust reso-nator.

5. Start the engine and verify properreverse and forward operation byshifting in and out of reverse threetimes.

Rear SuspensionThis procedure should be done every 40operating hours.

NOTE: Arctic Cat recommendsthat Arctic Cat All-Temp Grease (p/n4639-365) be used for this proce-dure.

1. Using Handlebar Stand (p/n 5639-152) or Steering Post Stand (p/n5639-946) or a suitable substitute,lay the snowmobile on its left side.

2. Lubricate all grease fittings with all-temperature grease.

5000/9000

CAUTIONWhen installing the shift actuator,rotate the actuator back and forth toproperly align it with the extensiongear. Failure to do so could causecomponent damage.

CAUTIONThe correct lubricant to use in thechain case is Arctic Cat SyntheticChain Lube. Any substitute maycause serious damage to the drivesystem.

28

MaintenancePeriodic Maintenance Checklist

Item Interval Page RemarksBrake System Daily 37 Check for binding, leakage, and proper operation;

lever firmness, travel, caliper, disc, and padsCooling System - Liquid Daily 14,32 Check for leakage, damage, obstructions, coolant

levelEngine Oil (5000/7000) 2500 Mi/

Seasonal30 Change oil and filter

Engine Oil (9000) 2000 Mi/Seasonal

31 Change oil and filter

Battery Daily 14,34 Check for proper charge and tight connectionsStop Switch Daily — Check for proper operationHoses Daily — Check for damage, leakage, and wearHeadlight & Taillight/Brakelight Daily 48-48 Check for proper operation and cleanlinessSteering System Daily — Check for proper operation, tightness of bolts,

and bindingThrottle Control System Daily 24 Check for binding, sticking, proper operation,

throttle cable tension, and wearDrive Belt Daily

Monthly41 Check for wear, cracks, and fraying

Check length and width dimensionsSki Wear Bars Daily 49 Check for wear and damageElectrical Wiring Weekly — Check for wear, damage, and tight connectionsExhaust System Weekly 14 Check for damage, leakage, and obstructionsNuts, Bolts, Fasteners Weekly — Check tightness Shock Absorbers Weekly 16,45 Check for fluid leakage and damage and air pres-

sure (Fox Air Shocks)Spark Plugs 3500 Mi 33 Check center electrode insulator color, carbon,

and gapValve Clearance (5000/9000) 5000 Mi/

Seasonal34 Check/adjust

Valve Clearance (7000) 25000 Mi 34 Check/adjustSuspension Weekly 45 Check for damage, loose components, and

proper adjustmentTrack Tension/Alignment Weekly 43,44 Check/adjust as necessaryWear Strips Weekly 50 Check for wear and damageWires & Cables Weekly — Check for wear, damage, and frayingFuel System - Tank, Pump, In-Line Filter, & Vent Hose

Weekly — Check for damage, wear, obstructions, and leak-age

Fuel Filter 5000 Mi/2 years

— Replace

Air Cleaner/Filter (9000) Weekly/Seasonal

29 Check/replace

Chain Case Daily 26 Check lube level and for leakageChain Case - Lubricant Seasonal 26 ReplaceHeat Exchangers Monthly — Check for wear, leakage, and damageDrive Clutch/Driven Clutch Monthly 16 Check for damage, binding, and wear/remove

drive belt, clean drive clutch/driven clutchRear Suspension Monthly 27 Grease

29

The longevity and safety of the snowmo-bile can be increased by making periodicchecks of the items in the precedingchecklist.

If, at any time, abnormal noises, vibra-tions, or improper working conditions ofany component of this snowmobile aredetected, DO NOT OPERATE THESNOWMOBILE. Take the snowmobileto an authorized Arctic Cat Snowmobiledealer for inspection and adjustment orrepair. If not under warranty, this serviceis at the discretion and expense of thesnowmobile owner.

The snowmobile should be taken to anauthorized Arctic Cat Snowmobile dealerat the end of each snowmobiling seasonfor general inspection and for off-seasonstorage servicing. This inspection andservicing is at the expense of the snow-mobile owner.

Air Cleaner/Filter (9000)The air filter inside the air cleaner housingmust be kept clean to provide good enginepower and gas mileage. If the snowmobileis used under normal conditions, inspectthe filter weekly and replace the filter atthe intervals specified. If operated inadverse conditions, inspect and service thefilter more frequently. Use the followingprocedure to remove the filter and toinspect and/or replace it.

1. Remove the left-side access panel;then remove the air filter from thehousing.

2. Inspect the air filter for dirt or damage.

3. Clean any debris from inside the airintake plenum.

4. Place the new filter (if necessary)into the housing; then install the left-side access panel.

Fuel System

In-Line Fuel Filter

Arctic Cat recommends that the in-line fuelfilter be replaced every 5000 miles. The fil-ter must be clean to allow the fuel hose totransmit the amount of gasoline required.

If the in-line fuel filter is obstructed, gas-oline flow will be restricted; therefore,the filter must be replaced. To removeand install the in-line fuel filter, use thefollowing procedure:

NOTE: Before removing the fuel fil-ter, take note that the filter is direc-tional and the arrow should bedirected towards the engine.

NOTE: On the 5000, the fuel filteris located below the steering sup-port. To access the filter, the hoodmust be removed.

CAUTIONFailure to inspect the air filter fre-quently if the snowmobile is used inadverse conditions can damage theturbocharger/engine.

CAUTIONDo not use compressed air in anattempt to clean the filter. Damage tothe filter may occur. If the filter isdirty, it must be replaced.

CAUTIONA torn air filter can cause damage to theturbocharger/engine. Contaminants mayget inside the turbocharger/engine if thefilter is torn. Carefully examine the filterfor holes or tears. Replace the filter witha new one if it is torn.

CAUTIONDo not run the engine without the airfilter installed. Severe damage to theturbocharger/engine will occur.

! WARNINGWhenever any maintenance orinspection is made on the fuel sys-tem in which there may be fuel leak-age, there should be no welding,smoking, open flames, etc., in thearea.

! WARNINGSince the fuel supply hose may beunder pressure, always wear safetyglasses; then remove the hose slowlyto release the pressure. Place anabsorbent towel around the connec-tion to absorb the fuel.

30

NOTE: On the 7000, the fuel filter islocated on top of the fuel tank. Toaccess the filter, the access panels,hood, and console need to be removed.

XM184

NOTE: On the 9000, the fuel filter islocated between the gas tank and therear belt guard and is secured to thetunnel with a filter bracket. To accessthe filter, the left-side access panelmust be opened and the lower con-sole must be unlatched and opened.

1. Remove the hose clamps and discard;then slowly remove the fuel hosesfrom the fuel filter. Dispose of theexcess fuel from the filter properly.

2. Inspect the fuel hoses thoroughly forany signs of cracking, cuts, or wearpoints.

3. Place the new hose clamps on thefuel hoses; then with the fuel pumpinlet and outlet noted, connect thefuel hoses to the fuel filter. Securewith the hose clamps.

NOTE: After completing the chang-ing of the fuel filter and the engine isstarted for the first time, inspect thefilter area for any signs of leaks.

0746-802

Gasoline Additives

Fuel de-icer can be used for all models.Arctic Cat Fuel Stabilizer (p/n 0436-907)should also be added to the last tank ofgasoline before storage.

Fuel Pickup Valves

If ever there is a restricted fuel flow and apickup valve is suspected, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for this service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.

Checking Engine Oil LevelNOTE: The engine must be atoperating temperature before check-ing the oil level or an incorrect oillevel will result.

1. Park the snowmobile on a level surface;then start the engine and allow to warmup for 5-10 minutes, or if the snowmo-bile was operated, allow the engine toidle approximately 30 seconds.

2. Shut the engine off; then remove theright-side access panel and verify oilis visible at least halfway up in thesight glass.

SNO-244A

3. If oil is not visible halfway up in thesight glass, add recommended engineoil until oil is visible half-way up thesight glass.; then on the 5000/9000,proceed to step 11 of ChangingEngine Oil/Filter in this sub-section.

CAUTIONMake sure the fuel filter is properlyseated into the holder located on thetunnel behind the driven shaft.

CAUTIONIf the engine and oil are not at operat-ing temperature, the oil will not bevisible in the sight glass. Tip thesnowmobile to the right at a 45°angle; then check to see if oil is pres-ent in the sight glass.

31

Changing Engine Oil/Filter

NOTE: Recycle or properly dis-pose of the used engine oil.

NOTE: The access panels and hoodmust be removed for this procedure.

1. Park the snowmobile on a level sur-face; then start the engine and allowit to warm up for 5-10 minutes, or ifthe snowmobile was operated, allowthe engine to idle for approximately30 seconds. Shut the engine off.

2. Remove the torx-head screws andthe access plate from beneath thesnowmobile.

3. Place a drain pan beneath the engine oilpan drain plug; then remove the plugand allow the oil to drain completely.

PC010A

XM125A

4. Using Oil Filter Wrench (p/n 0644-551), loosen (but do not remove) theoil filter and allow the oil to drainfrom the filter into the drain pan;then remove the filter.

NOTE: On the 9000, the oil filter isaccessible between the front open-ing of the chassis and the lowerintercooler hose.

5. Apply a light coat of fresh engine oilto the seal of the new oil filter.

6. Install the new oil filter by turningthe oil filter by hand until the sealhas contacted the oil filter mountingsurface; then tighten the oil filter to15 ft-lb (5000/9000) or 12 ft-lb(7000). Remove the drain pan.

7. Install the engine oil drain plug witha new gasket (if applicable); thentighten to 16 ft-lb (5000/9000) or 7.2ft-lb (7000).

8. Remove the four torx-head screwssecuring the right-side footrest to thetunnel and the support; then with adrain pan in position, remove thedrain plug from the oil tank.

746-121A

NOTE: To aid in draining the oilfrom the oil tank, position a funnelbetween the tank and the opening ofthe tunnel running board.

9. After the oil has drained completely,install the drain plug with a new O-ring and tighten to 16 ft-lb.

NOTE: On the 5000/9000, alwaysinstall a new Oil Pan Drain Plug Gas-ket (p/n 3402-011) and a new DrainPlug O-Ring (p/n 1602-213) whenchanging the oil.

10. Pour the recommended engine oilinto the oil tank.

CAUTIONCare must be taken not to over-fill thereservoir with oil.

! WARNINGCare must be taken if a hot drain plug isremoved by hand. Burning could occur.

5000/9000

7000

32

11. On the 5000/9000, open the airbleed bolt located on the oil pump(beneath the coolant tank) to purgeair from the oil hose.

PC016A

NOTE: When air can no longer beheard purging from oil pump bleed,tighten the bleed bolt to 7.5 ft-lb.

12. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position and theignition switch to the ON position.On the 5000/90000, the Oil PressureWarning Icon should illuminate.

NOTE: If the warning icon does notilluminate, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the dis-cretion and expense of the snowmo-bile owner.

13. If the warning icon illuminates (fromstep 12), start the engine. The warningicon should go out within five seconds.If it does, proceed to step 14.

NOTE: On the 7000, the enginemay need to be started 2-3 timesbefore it will stay running.

NOTE: If the warning icon does notgo out, shut the engine off immedi-ately and repeat step 11; then placethe ignition switch to the ON posi-tion and repeat step 13. If the warn-ing icon does not go out, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

14. Shut the engine off; then add oil tothe oil tank until oil is visible half-way up in the sight glass.

NOTE: If the oil and engine are notat operating temperature, the oillevel may read too low. Always makesure the engine is at operating tem-perature before checking the oil.

15. Install the access plate and torx-headscrews beneath the snowmobile;then install the hood and access pan-els.

Coolant LevelNOTE: Use a good quality, ethyl-ene glycol-based, automotive-typecoolant.

NOTE: Always check the coolantlevel with the engine cold.

7000

Locate the filler neck located above theresonator; then remove the coolant capfrom the filler neck. Verify that the coolantis at the bottom of the tab in the filler neck.

0747-547

NOTE: Under normal conditionschecking only the overflow tank(located above the drive clutch) isacceptable. Only if this tank does nothave coolant should the operatorhave to remove the hood and checkthe level at the filler neck.

Locate the coolant tank above the driveclutch; then remove the plug from thecoolant tank. Add coolant to the full levelon the tank. Install the plug.

CAUTIONDo not attempt to start the enginewith the bleed bolt open.

33

0747-766

5000/9000

NOTE: The access panels andhood must be removed for this pro-cedure.

1. Remove the filler cap from the cool-ant reservoir.

2. Verify the coolant level is at the bot-tom of the tab in the filler neck.

0746-117

3. If the coolant is below the tab, addcoolant to the reservoir until at the tab.

Spark PlugsNOTE: Always use the recom-mended spark plugs in the engine.See the appropriate specificationssheet for correct spark plug gap.

Varying terrain conditions and operatingusage may require spark plugs of a differ-ent heat range. For example, sustainedcross-country riding will usually requirecolder heat-range spark plugs while trailriding or other continual slow speedoperation will usually require hotter heat-range spark plugs.

NOTE: Spark plug maintenancemay be done by the snowmobileowner if qualified to do so. If theowner does not feel qualified, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forthis service. This service is at thediscretion and expense of the snow-mobile owner.

NOTE: For this procedure, thehood and side panels must beremoved.

1. On the 7000/9000, remove the sparkplug end caps; on the 5000, removethe two cap screws securing the igni-tion coils to the cylinder head cover.

2. Using a 3/8-in. drive ratchet,adapter, and a 5/8-in. spark plugsocket, remove the spark plugs.

NOTE: Prior to installing the sparkplugs, check the gap between theelectrode and ground strap. The clear-ance should be 0.9 mm (0.035 in.)(5000/9000) or 0.7-0.8 mm (0.028-0.031in.) (7000).

3. Install the spark plugs. Tighten to 96in.-lb.

4. On the 5000, install the ignitioncoils onto the cylinder head makingsure they are fully sealed. On the7000/9000, install the spark plugend caps.

CAUTIONIf the coolant is below the neck and ifcoolant has been added, immediatelyinspect for leakage and/or damage. Ifleakage or damage is detected, takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

CAUTIONIf the coolant is below the tab and ifcoolant has been added, immediatelyinspect for leakage and/or damage. Ifleakage or damage is detected, takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

CAUTIONIf adjusting spark plug gap is neces-sary, do not use the center electrodeas a leverage point. Damage to theplug may occur.

34

5. Install the hood and access panels.

Checking

To see if the spark plugs being used are ofthe proper heat range (after the snowmo-bile has been operated under normal driv-ing conditions), remove the spark plugsand examine the condition of the centerelectrode insulator of each spark plug.

AO352A

A. TAN or LIGHT BROWN insula-tor indicates correct spark plugs(heat range).

B. LIGHT GRAY or WHITE insula-tor indicates over-heating of theengine. This condition is caused bya too lean condition or incorrectspark plugs (heat range too hot).

C. BLACK insulator indicates fuelin the combustion chamber is notburning completely. This condi-tion is caused by a too rich con-dition, too much oil, or incorrectspark plugs (heat range too cold).

NOTE: If the center electrode insu-lators are light gray, white, or blackand if the ignition timing is correct,different heat-range spark plugs maybe necessary. Authorized Arctic CatSnowmobile dealers have detailedspark plug information. Consult adealer before changing spark plugs,as incorrect heat-range spark plugscould cause poor engine performanceor engine damage.

Checking/Adjusting Valve ClearanceAfter 5000 miles or prior to seasonalstorage (5000/9000) or 25000 miles(7000), valve clearance should bechecked and adjusted as necessary.

NOTE: Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service.This service is at the discretion andexpense of the snowmobile owner.

BatteryThese sealed batteries after being in ser-vice require regular cleaning andrecharging in order to deliver peak per-formance and maximum service life. Thefollowing procedures are recommendedfor cleaning and maintaining sealed bat-teries. Always read and follow instruc-tions provided with battery chargers andbattery products.

NOTE: Battery maintenance maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

To remove and charge the battery, use thefollowing procedure:

CAUTIONIf a spark plug is light gray, white, orblack and another is tan or light brown,take the snowmobile to an authorizedArctic Cat Snowmobile dealer forinspection and service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

CAUTIONIt is critical that the checking/adjust-ing valve clearance be done at therecommended intervals or severeengine damage may occur.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns,or blindness as a result of an explo-sion. Always remove rings andwatches. Any time service is per-formed on a battery, the followingmust be observed: keep sparks, openflame, cigarettes, or any other flameaway. Always wear safety glasses.Protect skin and clothing when han-dling a battery. When servicing a bat-tery in an enclosed space, keep thearea well-ventilated.

35

1. Remove the torx-head screw fromthe rear underside of the seat; thenremove the seat.

2. Remove the negative battery cableand ground wire; then remove thepositive cable.

NOTE: For installing purposesprior to removing the battery, notethe routing and securing locations ofthe cables and harness wires.

3. Remove the two screws and locknuts securing the battery bracket/solenoid to the seat-base; then movethe bracket up and out of the wayand remove the battery.

746-170A

4. Thoroughly wash the battery withsoap and water; then using a wirebrush, clean the battery posts andcable ends removing all corrosivebuildup. Replace damaged cables orcable ends.

NOTE: If battery posts or cableends have a build-up of white/greenpowder residue, apply water andbaking soda to neutralize acid; thenflush off with warm soapy water.

5. Using a multimeter, test battery voltage.The meter must read no less than 12.5DC Volts for a fully charged battery.

NOTE: At this point if the meterreads as specified, the battery maybe returned to service (see step 9).

6. If the meter reads less than specifiedvoltage, charge the battery using thefollowing guidelines.

A. When using an automatic batterycharger, always follow the char-ger manufacturer’s instructions.

B. When using a constant-currentbattery charger, use the follow-ing Battery Charging Chart.

! WARNINGBattery posts, terminals, and relatedaccessories contain lead and leadcompounds, chemicals known to thestate of California to cause cancerand reproductive harm. Wash handsafter handling.

CAUTIONOn the LXR, make sure to disconnectthe seat heater harness connectorprior to removing the seat.

! WARNINGAvoid spillage and contact with skin,eyes, and clothing.

CAUTIONDo not charge the battery while it is inthe snowmobile with the battery ter-minals connected.

CAUTIONDo not remove seal strip on a sealedbattery.

! WARNINGBattery acid is harmful if it contactseyes, skin, or clothing. Care must betaken whenever handling a battery.

CAUTIONNever exceed the standard chargingrate.

! WARNINGAn overheated battery could explodecausing severe injury or death.Always monitor charging times andcharge rates carefully. Stop chargingif the battery becomes very warm tothe touch. Allow it to cool beforeresuming charging.

36

NOTE: If the battery voltage is 11.5DC Volts or less, some chargers may“cut off” and fail to charge. If thisoccurs, connect a fully chargedbooster battery in parallel (positive topositive and negative to negative) fora short period of time with the chargerconnected. After 10-15 minutes, dis-connect the booster battery leavingthe charger connected and the char-ger should continue to charge. If thecharger “cuts off,” replace the battery.

7. After charging the battery for thespecified time, remove the batterycharger and allow the battery to sitfor 1-2 hours.

8. Connect the multimeter and test thebattery voltage. The meter shouldread no less than 12.5 DC Volts. Ifthe voltage is as specified, the bat-tery is ready for service.

NOTE: If voltage in step 8 is belowspecifications, charge the battery anadditional 1-5 hours; then retest. Thebattery is ready for service.

9. Place the battery into position in thesnowmobile; then coat the batteryposts and cable ends with a lightcoat of multi-purpose grease.

10. Secure the red positive cable to thepositive terminal on the batteryusing a cap screw, lock washer, anda flat washer. Tighten securely.

11. Secure the main black negativecable and the small black negativecable to the battery using a capscrew, lock washer, and a flatwasher. Tighten securely.

NOTE: Assure the harness wires andcables are routed properly as notedduring removing battery procedure.

XM015A

XM167A

12. Install the battery bracket/solenoidand tighten the two screws and locknuts to 105 in.-lb; then install theseat and secure with the torx-headscrew. Tighten securely.

NOTE: On the LXR prior to lower-ing and securing the seat, connectthe seat heater harness connector.

Battery Charging Chart(Constant-Current Charger)

Battery Voltage

(DC)

ChargeState

Charge Time Required (at 1.5-

2.0 Amps)

12.5 (mini-mum)

100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

CAUTIONBefore installing the battery, makesure the ignition switch is in the OFFposition.

CAUTIONConnecting cables in reverse (posi-tive to negative and negative to posi-tive) can cause serious damage tothe electrical system.

5000/9000

7000

37

Fuses

Fuses protect the snowmobile electricalsystem from overloading. If electricalparts in the snowmobile are not working,the system may have been overloaded andcaused a blown fuse. Before repairing orreplacing any electrical part, check theappropriate fuses. If a fuse blows (opens acircuit), all the parts of the snowmobilethat use that circuit will not work.

Once which fuse to check has been deter-mined, perform the following steps:

1. Locate the fuse block and removethe fuse block cover.

NOTE: To locate the fuse block onthe 5000/9000, open the left-sideaccess panel; the fuse block isabove the belt guard. On the 7000,the fuse block is behind the coolantoverflow bottle.

PC004A

XM124A

NOTE: There are spare fusesbeneath the fuse block cover.

2. Remove the suspected fuse.

NOTE: Fuse function descriptionsare next to the fuse contacts in thefuse block.

3. Look through the clear side of thefuse to see if the element inside isburned or separated. If it is, the fuseis blown and should be replacedwith a fuse of the correct amperagerating.

4. Install the fuse block cover and closethe access panel.

Even after replacing a fuse, it may con-tinue to blow if the cause of the overloadis not determined. If the fuse continues toblow, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

Brake SystemArctic Cat recommends that the brakesystem (brake lever, fluid reservoir, hose,caliper, pads, and brake disc) be checkeddaily for fluid leakage, wear, or damageand for proper operation. Also, the brakefluid level must be checked every timebefore starting the engine.

Checking/Adding Brake Fluid

1. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. Thebrake fluid level must be at the highbrake fluid mark in the reservoir.

5000/9000

7000

! WARNINGAlways replace a fuse with one hav-ing the same specified amperage rat-ing. Using a fuse with a higher ratingcan cause severe wire damage andcould start a fire.

! WARNINGDO NOT operate the snowmobilewhen the brake lever lock is engagedor when any component in the brakesystem is damaged, worn, oradjusted improperly. If the snowmo-bile is operated and the brake systemis not functioning properly, severepersonal injury could result.

38

745-817A

2. If the brake fluid is below the highbrake fluid mark, add Arctic Catapproved DOT 4 brake fluid untilthe fluid is at the recommendedlevel. Install and secure the reservoircover. Do not allow moisture to con-taminate the brake system.

Changing Brake Fluid

The brake fluid must be changed on aregular basis and whenever the brakefluid has been overheated or contami-nated. The brake fluid should be changedevery 1000 miles or at the end of thesnowmobiling season, whichever occursfirst. Take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forthis service. This service is at the discre-tion and expense of the snowmobileowner.

Checking Brake Lever Travel

Before each use, check the brake levertravel using the following procedure:

1. Compress the brake lever fully.

NOTE: Do not pump the brakelever as it will produce an inaccuratereading.

2. Measure the distance between the brakelever and the handlebar. The distancemust be greater than 2.54 cm (1 in.).

0745-816

3. If the resultant distance is less thanspecified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

Bleeding Brake System

If the brake lever feels spongy whenapplied, the brake system may need to bebled. To bleed the brake, use the follow-ing procedure:

NOTE: The brake system may bebled by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

1. Remove the reservoir cover and (ifnecessary) fill the reservoir to thehigh brake fluid mark with ArcticCat approved DOT 4 brake fluid.


! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Arctic Catapproved DOT 4 brake fluid. Neversubstitute or mix different types orgrades of brake fluid. Brake loss canresult. Brake loss can result in severeinjury or even death.

! WARNINGDo not operate the snowmobile if thecompressed distance between thebrake lever and the handlebar is lessthan 2.54 cm (1 in.). Brake loss mayoccur. Brake loss can result in severepersonal injury.


39

2. Slide a piece of flexible tubing overthe ball of the bleeder valve anddirect the other end into a container.

XM145A

3. Slowly compress the brake leveruntil maximum pressure is attained;then hold the lever in the com-pressed position to maintain pres-sure. Open the bleeder valve torelease the fluid and air. When thefluid stops, close the bleeder valve;then release the brake lever.

4. Repeat step 3 until the brake fluidflows free of air bubbles.

NOTE: It may be necessary to refillthe reservoir during the bleedingprocess. Never allow the brake fluidto go below the low brake fluid markin the reservoir.

5. When the brake fluid is free of all airand the brake lever feels firm whencompressed, fill the reservoir to thehigh brake fluid mark; then install andsecure the cover. Remove the tubefrom the bleeder valve.

Checking/Changing Brake Pads

The condition of the brake pads must bechecked daily and changed if worn ordamaged. To check and change the brakepads, use the following procedure:

NOTE: The brake pads may bechanged by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

NOTE: When installing new brakepads, always install them as a set.Never install just one pad or usebrake pads which have been used inanother snowmobile.

1. Remove the brake fluid reservoir cover;then remove most of the brake fluidfrom the reservoir. Install the cover.

NOTE: The above procedure willallow room for the fluid from the cali-per when the pistons are pushedinto the caliper for installing newbrake pads. Replacing the cover willprevent fluid spillage.

2. Open the left-side access panel andremove the rear belt guard. Removethe driven clutch.

3. Remove the two torx-head screwssecuring the brake shield to the beltguard mount; then remove the capscrews securing the brake shield tothe brake caliper.

4. Carefully move the shield out of theway; then remove the hairpin clipsecuring the brake pads to the cali-per assembly.

5. Using a pair of pliers, pull the outerbrake pad out of the caliper assembly.

PC013

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Any substitute may resultin a loss of brakes.


40

NOTE: Changing one pad at a timewill prevent one piston from pushingout the other piston from the caliper.

6. Measure the thickness of the brakepad. The brake pad thickness mustbe greater than 5.0 mm (0.20 in.). Ifthe brake pad thickness is less thanspecified, replacement of both padsis necessary.

PC011A

7. Using a flat-blade tool, slowly andcarefully push the piston into thecaliper.

8. Position the outer brake pad into thecaliper; then install the hair-pin clipinto the caliper assembly.

9. Repeat steps 5-8 for the inner pad; thensecure the pad with the hairpin clip.

10. Remove the reservoir cover andremove the remaining fluid; then fillthe reservoir with fresh fluid andinstall the cover.

11. Pump the brake lever to ensure cor-rect positioning of the brake padsand proper brake lever travel; thenrelease.

NOTE: If brake lever travel is notwithin specification, bleed the brakesystem.

12. Remove the reservoir cover and fillthe reservoir (if necessary) to theproper level with fresh brake fluid;then install the cover.

13. Secure the brake shield, the drivenclutch (tightened to 20 ft-lb), and therear belt guard; then close andsecure the left-side access panel.

NOTE: When new brake pads areinstalled, a “burnishing” process isrequired (see Burnishing Brake Padssub-section).

Burnishing Brake PadsAfter changing brake pads, the new brakepads must be burnished to achieve fullbraking effectiveness. Braking distancewill be extended until brake pads areproperly burnished.

To properly burnish the brakes, use fol-lowing procedure:

1. Choose an area sufficiently large tosafely accelerate to 30-40 mph andto brake to a stop.

NOTE: This procedure can also beaccomplished using a shielded jackstand.

2. Accelerate to 30-40 mph; then com-press brake lever to decelerate to a stop.

NOTE: Lightly apply the brakelever to come to an easy stop; do notover-apply brakes or “lock up” thetrack.

3. Repeat procedure 10-15 times allowingsome cooling between stops.

NOTE: Do not repeat too soon ortoo aggressively as to get the brakedisc “red hot.”

NOTE: This procedure stabilizesthe pad material and extends the lifeof the pads.

Chain Tension (7000)1. Remove the right side access cover;

then remove the exhaust assembly.

2. Loosen the jam nut.

3. Turn the chain tension adjustmentbolt clockwise until it is finger tight;then loosen it 1 1/2 turns.

! WARNINGDo not attempt sudden stops or putyourself into a situation where a sud-den stop will be required until thebrake pads are properly burnished.

41

0747-831

4. While holding the bolt with a wrench,tighten the jam nut to 18 ft-lb.

5. Install the exhaust assembly with anew gasket.

6. Install the right-side access cover.

NOTE: Check that the harness isinstalled correctly.

Drive BeltThe drive belt transfers power from thedrive clutch to the driven clutch. If thebelt is worn, cracked, or stretched, maxi-mum power will not be transmitted andthe belt could also fail and therefore mustbe replaced. Periodic checks (at leastonce a month under normal usage) of twodrive belt specifications are essential.

1. Measure the outside circumferenceof the drive belt. The belt should bewithin the recommended range incircumference (see appropriate spec-ifications sheet).

2. Measure the outside width of thedrive belt. The belt should be withinthe recommended range in width.

3. Check the belt for cracking, fraying, etc.

If any of the specifications or conditionsare unsatisfactory, replace the drive belt.

NOTE: Drive belts should be pur-chased from an authorized Arctic CatSnowmobile dealer, as Arctic Cat drivebelts are made to exact specificationsand of quality material. Belts made byother manufacturers may not be of thesame specifications or quality and,therefore, usage could result in poorperformance and premature belt failure.

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt.

Also, new drive belts have a break-inperiod of approximately 25 miles. Afterinstalling a new drive belt, drive thesnowmobile for 25 miles at 3/4 throttle orless. By revving the engine up and down(but not exceeding 60 mph), the exposedcord on the side of a new belt will beworn down. This allows the drive belt togain its optimum flexibility and willextend drive belt life.

Checking/Adjusting Drive Belt Deflection

SNO-276A

The drive belt must have the proper fit inthe drive clutch and driven clutch. Tocheck for proper drive belt fit, use thefollowing procedure.

1. Place a straightedge on the top of thedrive belt. The straightedge shouldreach from the drive clutch to the topof the driven clutch.

NOTE: Make sure the drive belt isall the way out in the driven clutchbefore checking drive belt deflection.

2. Using a stiff ruler centered betweenthe drive clutch and driven clutch,push down on the drive belt justenough to remove all slack and notethe amount of deflection. The deflec-tion should be within the range of28.5-31.8 mm (1 1/8-1 1/4 in.).

CAUTIONNever run the engine with the drivebelt removed. Excessive revving of theengine could result in serious enginedamage and drive clutch failure.

42

3. To correct drive belt deflection,remove the sheave adjuster from theclutch, remove or add shim washers tothe adjuster, and install the adjuster.

NOTE: Adding shim washers willdecrease belt deflection and removingshim washers will increase belt deflec-tion. Available shim washers from Arc-tic Cat are p/n 0648-714 (0.090 in.) - oneincluded in the tool kit, p/n 0648-715(0.030 in.), and p/n 0648-716 (0.060 in.).

NOTE: Removing/adding shim wash-ers may be done by the snowmobileowner if qualified to do so. If the ownerdoes not feel qualified, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

Removing Drive Belt

NOTE: Changing a drive belt can bedone by the snowmobile owner if qual-ified to do so. If the owner does notfeel qualified, take the snowmobile toan authorized Arctic Cat Snowmobiledealer for this service. This service isat the discretion and expense of thesnowmobile owner.

1. Turn ignition key to the OFF positionand wait for all moving parts to stop.

2. Set the brake lever lock.

3. Open the left-side access panel.

4. Remove the cap screw, lock washer,washer, and sheave adjuster from theend of the driven clutch; then removethe sheave adjuster from the capscrew.

0743-395

NOTE: Each time the driven clutchcap screw is removed, the hole in thedriven shaft should be cleaned freeof any Loctite residue.

NOTE: Verify the shims and O-ringare not removed from the adjuster.

5. Remove the lock washer and flatwasher from the cap screw and reversethe sheave adjuster.

6. Install the cap screw into the drivenclutch; then tighten the cap screw untilthe movable sheave opens far enough toallow the belt to be removed.

7. Remove the drive belt from the drivenclutch first; then from the drive clutch.

NOTE: Before installing the drivebelt, use a suitable cleaning solvent tothoroughly clean the sheaves.

Installing Drive Belt

NOTE: If a new drive belt is beinginstalled, see Drive Belt Break-In sub-section in the General Informationsection.

1. Place the drive belt (so the part num-ber can be read and the arrows are fac-ing the front of the snowmobile)between the sheaves of the driveclutch first; then between the sheavesof the driven clutch.

2. Install the cap screw, lock washer,washer, and sheave adjuster back intothe driven clutch. Tighten the capscrew (apply a few drops of blue Loc-tite #243 to the threads) to 20 ft-lb.

3. Install the left-side access panel.

4. Release the brake lever lock.

CAUTIONBefore securing the driven clutch, besure the rollers are up against thetorque bracket or damage to the back-side cams may occur.

! WARNINGNever operate the snowmobile with-out the belt guard/access panelsecured in place.

43

Track TensionTrack tension is directly related to the overallperformance of the snowmobile. If the trackis too loose, it may slap against the tunnelcausing wear or it may “ratchet” on the trackdrive sprockets. If extremely loose, the idlerwheels may climb over the track lugs forcingthe track against the tunnel causing the trackto “lock.” Arctic Cat recommends that thetrack tension be checked daily during the first300 miles of operation and once a weekthereafter and adjusted according to need.The track will stretch and take a “set” duringbreak-in. Track deflection must be main-tained within the recommended range.

Checking Track Tension

1. Remove excess ice and snow buildupfrom the track, track drive sprockets,and the inside of the skid frame.

2. Elevate the snowmobile on ashielded safety stand high enough touse a spring scale.

3. At the mid-point of the track (on thebottom side), hook a spring scalearound a track clip; then pull downon the scale to the recommendedpressure (see chart). Measure thedeflection (distance) between thebottom of the wear strip and theinside surface of the track clip. Mea-surement should be 2.0 in.

746-788A

NOTE: Measurement is from thebottom of the wear strip at the pointof the shock pad on the slide rail.

NOTE: Only tighten track until thetrack does not ratchet. Too tight of atrack will cause the rear suspensionto not work properly.

Adjusting Track Tension

NOTE: To ensure proper track tensionadjustment, perform all adjustments onboth sides of the snowmobile.

1. Loosen the idler wheel axle capscrews.

0745-811

2. If the deflection (distance betweenthe bottom of the wear strip and theinside surface of the track clip)exceeds specifications, tighten theadjusting bolts to take up excessiveslack in the track.

3. If the distance between the bottom ofthe wear strip and the inside surfaceof the track clip is less than specified,loosen the adjusting bolts to increasethe slack in the track.

4. Check track alignment.

! WARNINGTrack tension must be properly main-tained. Personal injury could result ifa track is allowed to become exces-sively loose.

! WARNINGDO NOT attempt to check or adjusttrack tension with engine running.Turn ignition key to the OFF position.Personal injury could result fromcontact with a rotating track.

Track Tension

129” 20 lb

137” 25 lb

141”/153”/162” 14-15 lb CAUTIONAlways maintain track tension withinrecommended specification.

44

5. After proper track tension isobtained, tighten the idler wheelaxle cap screws to 34 ft-lb; thentighten the adjusting bolts securelyagainst the axle.

NOTE: Since track tension andtrack alignment are interrelated,always check both even if only oneadjustment seems necessary.

Track AlignmentProper track alignment is obtained whenthe rear idler wheels are equal distancefrom the inner track drive lugs. Excessivewear to the idler wheels, drive lugs, andtrack will occur if the track is improperlyaligned. Arctic Cat recommends that thetrack alignment be checked once a weekor whenever the track tension is adjusted.

Checking Track Alignment

1. Remove excess ice and snowbuildup from the track, track drivesprockets, and the inside of the skidframe.

2. Position the tips of the skis against awall; then using a shielded safetystand, raise the rear of the snowmo-bile off the floor making sure thetrack is free to rotate.

3. Start the engine and accelerateslightly. Use only enough throttle toturn the track several revolutions.SHUT ENGINE OFF.

NOTE: Allow the track to coast to astop. DO NOT apply the brakebecause it could produce an inaccu-rate alignment condition.

4. When the track stops rotating, checkthe relationship of the rear idlerwheels and the inner track drive lugs.If the rear idler wheels are centeredbetween the inner track drive lugs, noadjustment is necessary.

0745-809

5. If the idler wheels are not centeredbetween the inner track drive lugs,an adjustment is necessary.

Adjusting Track Alignment

1. On the side of the track which hasthe inner track drive lugs closer tothe rear idler wheel, loosen the idlerwheel axle cap screw; then rotate theadjusting bolt clockwise 1 to 1 1/2turns.

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

! WARNINGMake sure the ignition key is in theOFF position and the track is notrotating before checking or adjustingtrack alignment. Personal injurycould result if contact is made with arotating track.

! WARNINGThe tips of the skis must be posi-tioned against a wall or similarobject.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

45

0745-811

2. Check track alignment and continueadjustment until proper alignment isobtained.

NOTE: Make sure correct tracktension is maintained after adjust-ing track alignment (see Track Ten-sion sub-section in this section).

3. After proper track alignment isobtained, tighten the idler wheelaxle cap screw to 34 ft-lb; thentighten the adjusting bolts securelyagainst the axle.

4. Field test the track under actual con-ditions.

5. After the field test, check the align-ment of the track. If additional adjust-ment is necessary, repeat AdjustingTrack Alignment procedure.

SuspensionThe suspension should be adjusted forthe operational needs and riding prefer-ence of the operator.

The front shock springs determine theamount of ski pressure and the reactionof the front suspension to rough terrain.The amount of ski pressure can also bechanged by adjusting the length of theskid frame front arm limiter straps.

On standard models, the rear arm shockabsorber spring influences the load carry-ing capability of the snowmobile andshould be adjusted for the weight and rid-ing preference of the operator.

NOTE: On Sno Pro models with arear arm float shock, this adjustmentis achieved by increasingly ordecreasing the air pressure in therear arm air shock absorber.

Adjusting Front (Ski) Shock Springs

The front (ski) shock springs are individu-ally adjustable for the terrain conditions anddriving style of the operator. The springadjuster nut has been set at the factory so thecorrect amount of threads are exposedbetween the adjuster nut and the threadedshock body as an initial setting. Additionalski pressure can be obtained by tighteningthe spring tension; ski pressure can bedecreased by relaxing spring tension.

NOTE: Equal adjustments shouldbe maintained on both sides of thesnowmobile.

Front (ski) shock spring pre-load adjust-ment is accomplished by loosening theadjuster nut locking collar (B) from theadjuster nut (A) and using the SpringAdjuster Tool from the tool kit, rotatingthe adjuster nut in whichever direction isdesired. Tighten the locking collaragainst the adjuster nut.

0745-159

Adjusting Fox Air Shocks (Sno Pro Models)

NOTE: It is recommended to moni-tor the air pressure in the air shocksonce every month. If air must beadded to the shock, use the shockpump located in the rear compart-ment of the seat.

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

46

NOTE: Adjusting air shocks maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

The air shocks are individually adjustablefor the terrain conditions and drivingstyle of the operator. The shocks are pre-set at the factory (see chart) as an initialsetting; however, it is possible to “finetune” the shocks to match the operator’sweight, riding style, and terrain condi-tions.

NOTE: Adding air pressure willincrease the air spring force; reduc-ing air pressure will decrease airspring force.

Checking and adjusting air pressure mustbe done at riding temperature (outside).Also, it is advisable to check air pressurewhen the outside temperature variesmore than 25°.

NOTE: Care should be taken tohave equal pressure in the front (ski)shocks before operating the snow-mobile.

To increase or decrease air pressure, usethe following procedure.

NOTE: When adjusting air pres-sure, all weight must be removedfrom the suspension, and the shockabsorbers must be fully extended.

1. Remove the air valve cap from theshock.

2. Thread the valve of Shock AbsorberAir Pump onto the shock air valveapproximately six rotations.

NOTE: As the pump is beingattached to the shock, the hose willfill with air. This will result in a lowergauge pressure 2-5 psi.

3. To decrease air pressure in theshock, press the black bleed valvebutton half way down and hold untildesired pressure is attained.

NOTE: Pressing the button fullydown and releasing it will allow onlya small amount of air to escape(micro-adjust).

4. To increase air pressure in the shock,pump until desired pressure isattained.

5. Remove the pump valve from theshock air valve.

NOTE: As the pump valve is beingremoved from the shock, the soundof air loss is from the pump hose,not from the shock.

6. Install the air valve cap onto the shock.

Initial Setting Chart

Model Front Shock (Ski)

Rear Arm Shock

XF/ZR Sno Pro 75 psi N/A

XF High Country/M Sno Pro/M LTD

90 psi 145 psi

XF Cross Country 75 psi 145 psi

XF Cross-Tour N/A 145 psi

XF Cross-Tour OS

75 psi 145 psi

ZR RR 100 psi (Main Chamber)

200 psi (Evol Chamber)

N/A

XF Cross Tour Rear Shock Setting Chart

Operator Weight Rear Shock Pressure (psi)

190 Shop @ 70°F 145 psi

Trail @ 20°F130 psi

Passenger Weight Rear Shock Pressure (psi)

100 Shop @ 70°F 155 psi


140 Shop @ 70°F 165 psi


180 Shop @ 70°F 170 psi


220 Shop @ 70°F 180 psi


47

Adjusting Skid Frame Front Arm

The skid frame front arm shock spring ten-sion and the limiter straps are adjustable.However, Arctic Cat recommends that theshock spring be maintained at the factorypreset of 1/8-1/4 in. preload. Tightening theskid frame front arm shock spring maycause improper balance and may ruin thehandling features of the snowmobile.

The length adjustment of the front arm lim-iter straps determines the weight distributionbetween the front of the skid frame and theskis. Tightening the limiter strap (shorteningthe strap) will pull up on the front of the skidframe and will increase ski pressure. Loos-ening the limiter strap (lengthening thestrap) lowers the front of the skid frame anddecreases ski pressure.

When customizing the amount of skipressure, be sure to adjust both strapsequally and do not over-adjust the limiterstraps to adversely affect steering andoperator control of the snowmobile.Some experimentation may be requireduntil the proper adjustment for the opera-tor’s individual style is obtained.

NOTE: If the limiter straps areadjusted, it is highly recommended thatat least a minimum of 1/8 in. preload onthe shock spring be maintained.

Adjusting Rear Spring Pre-Load (ZR)

Proper adjustment of rear spring pre-loadis necessary to get the most desirableride. The chart is designed to help in set-ting up rear spring pre-load; however,riding style is the single greatest factor indetermining rear spring requirements.

NOTE: These cam position set-tings are suggestions only. Personalriding style will greatly influencecam position settings. Spend time todetermine setting preferences.

Rear spring pre-load adjustment is accom-plished by rotating the adjusting cams.Position 3 provides the stiffest ride, andposition 1 is for the light driver or slow-speed trail riding. Position 2 is for theaverage operator under normal conditions.Always rotate the cam from the lighterposition to the heavier position.

741-450A

To rotate an adjusting cam, use the sparkplug wrench from the tool kit. Rotate thewrench until the cam is in the desiredposition. To stiffen the ride, rotate the camso as to raise the spring end. Make theappropriate adjustment on the other cam.

Adjusting Skid Frame Rear Arm Shock Spring (M/XF)

Proper adjustment of rear arm shockabsorber spring pre-load is necessary toget the most desirable ride.

The rear arm shock spring is adjustablefor the terrain conditions and drivingstyle and weight of the operator. Thespring adjuster nut has been set at the fac-tory so the correct amount of threads areexposed between the adjuster nut and thethreaded shock body as an initial setting.

! WARNINGDo not adjust the front arm limiterstraps to a point at which steeringand operator control of the snowmo-bile are adversely affected.

Rider Weight (lb) Cam Position

Up to 180 1

180-240 2

Over 240 3

CAUTIONNever force the adjustment camsfrom the low position to the highposition. Cam damage may occur.

48

Rear spring pre-load adjustment isaccomplished by loosening the adjusternut locking collar (B) from the adjusternut (A) and using the Spring AdjusterTool from the tool kit, rotating theadjuster nut in whichever direction isdesired. Tighten the locking collaragainst the adjuster nut.

0745-159

LightsFor the correct headlight bulb and/or tail-light/brakelight LED, see the appropriatespecifications sheet.

Removing and Installing Taillight/Brakelight

These models are equipped with an LEDtaillight/brakelight. If the LED fails, itmust be replaced. To remove and installthe LED, use the following procedure.

746-097B

1. Disconnect the taillight harness con-nector.

2. Remove the two torx-head screwssecuring the taillight to the bracket.

3. Connect the taillight harness connec-tor; then secure the taillight to thebracket with the two torx-head screws.

Removing/Installing Headlight Bulb

NOTE: The bulb portion of headlightis fragile. HANDLE WITH CARE. Whenreplacing the headlight bulb, the bulbassembly must first be removed fromthe housing. Do not touch the glassportion of the bulb. If the glass istouched, it must be cleaned with a drycloth before installing.

1. Disconnect the headlight harnessconnector from the bulb; thenremove the rubber grommet fromthe headlight housing.

2. Rotate the bulb retainer counter-clockwise until it unlocks from thehousing; then remove the bulb.

0746-096

3. Install the bulb and retainer; thenrotate the retainer clockwise until itproperly locks in place.

4. Install the rubber grommet; thenconnect the headlight harness con-nector to the bulb.

5. Check headlight aim.

Adjusting Headlight Aim

The headlight can be adjusted for verticalaim of the HIGH/LOW beam. The geo-metric center of HIGH beam zone is to beused for vertical aiming.

1. Position the snowmobile on a levelfloor so the headlight is approxi-mately 8 m (25 ft) from an aimingsurface (wall or similar surface).

! WARNINGDo not operate the snowmobileunless headlight beam is adjustedproperly. An incorrectly adjustedbeam will not provide the operatorthe optimum amount of light.

49

NOTE: There should be an “aver-age” operating load on the snowmo-bile when adjusting headlight aim.

2. Measure the distance from the floorto midpoint of the headlight.

3. Using the measurement obtained instep 2, make a horizontal mark onthe aiming surface.

4. Make a vertical mark which intersectsthe horizontal mark on the aiming sur-face directly in front of the headlight.

5. Engage the brake lever lock and startthe engine. Move the headlight dimmerswitch to the HIGH beam position. DONOT USE LOW BEAM.

6. Observe the headlight beam aim.Proper aim is when the most intensebeam is centered on the vertical mark 5cm (2 in.) below the horizontal markon the aiming surface.

0745-813

7. Adjust the headlight using the adjust-ing screw on the backside of the head-light using a 4 mm swivel socket andlong extension until correct aim isobtained. Shut the engine off; then dis-engage the brake lever lock.

0746-807

Ski Wear BarsThe ski wear bar is a replaceable barattached to the underside of the ski. The pur-pose of the wear bar is to assist in turning thesnowmobile, to minimize ski wear, and tomaintain good steering control. If the snow-mobile is operated primarily in deep snow,ski wear bar wear will be minimal; however,if the snowmobile is operated on terrainwhere the snow cover is minimal, the skiwear bar will wear faster. To maintain posi-tive steering characteristics, Arctic Cat rec-ommends that the ski wear bars be checkedbefore each use and replaced if worn beyond1/2 of the original diameter. Ski wear barsare available from an authorized Arctic CatSnowmobile dealer.

Removing Ski Wear Bars

1. Using Front End Lift (p/n 5639-151),elevate the front of the snowmobile.

2. Remove the lock nuts securing thewear bar to the ski.

0743-185

3. Remove the wear bar from the ski.

Installing Ski Wear Bars

1. Move the wear bar into position onthe bottom of the ski.

NOTE: If installing a double-offsetwear bar, the carbide edge should bedirected to the outside of the ski.

2. Align the wear bar studs with theholes in the ski; then install the locknuts. Tighten to 15 ft-lb.

! WARNINGOperating the snowmobile withexcessively worn ski wear bars mayresult in a loss of steering control.

50

Adjusting Ski StanceNOTE: Local laws and/or regula-tions as to maximum width of the skistance on these snowmobiles maybe applicable. Always comply withthe maximum width laws and/or reg-ulations when adjusting ski stance.

NOTE: Ski stance can be increased/decreased by 2.5 cm (1.0 in.).

1. Place the front of the snowmobile ona support stand.

2. Remove the cotter pin; then removethe slotted nut and cap screw secur-ing the ski assembly to the spindle.Remove the ski. Account for therubber damper, inserts, and washers.

3. To increase ski stance, place skistance spacer to the outside of thespindle and adjust the damper.

0746-797

4. To decrease ski stance, place skistance spacer to the inside of thespindle and adjust the damper.

0746-796

5. Apply an all-temperature grease to thenon-threaded portion of the capscrew; then slide the cap screwthrough the ski accounting for the rub-ber damper, inserts, and washers.

NOTE: Install the cap screw so the nutwill be located to the inside of the ski.

6. If using the existing nut, apply red Loc-tite #271 to the threads of the capscrew; then tighten the nut to 45 ft-lb.

7. Place new cotter pin into the ski capscrew and spread the pin.

8. Repeat procedure for the other ski.

Rail Wear StripsArctic Cat recommends that the wear stripsbe checked weekly and replaced as neces-sary. Measure the wear strips at 25.4 cm (10in.) intervals. Wear strips must be 10.7 mm(0.42 in.) thick or thicker.

0745-807

If wear strip measurements are less thanspecified, replacement of both wear stripsis necessary to prevent premature trackclip wear and possible track damage.Take the snowmobile to an authorizedArctic Cat Snowmobile dealer for thisservice. This service is at the discretionand expense of the snowmobile owner.

Each time a new set of wear strips areinstalled, they should be tempered. Temperthe wear strips by driving the snowmobilefor approximately a mile on a hard packtrail; then immediately drive into deep snowand allow the wear strips to cool. Repeat theprocedure (warming up the wear strips; thencooling them down) two or three times.

NOTE: The rail wear strips will wearrapidly if the snowmobile is operatedon terrain on which the snow cover isminimal. Loose snow is required tocool and lubricate the wear strips andprevent accelerated wear.

NOTE: Two Wheel Kit (p/n 6639-184)and Four Wheel Kit (p/n 5639-995) areavailable to reduce wear strip wear.

NOTE: If operating on ice or hard-packed snow conditions, it is recom-mended that Ice Scratchers (p/n 5639-897) be installed to reduce wear stripwear and engine overheating.

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Performance TipsOperating a high performance snowmo-bile requires a special attention that is notrequired by a low performance snowmo-bile. Often, a minor adjustment willresult in a large increase in performance.This section is intended to highlightminor conditions that adversely affectperformance and the adjustments neededto correct them. Be sure, however, tothoroughly read and understand thisentire manual especially the section onspark plugs, track tension and alignment,and suspension.

DRIVE BELT — This link between theengine and drive train is often the mostneglected component. The drive belt musthave the proper fit in the drive clutch anddriven clutch. Proper fit is when the topsurface of the drive belt is flush with thetop or up to 1/16 in. higher than the drivenclutch sheaves (with the sheaves fullyclosed). If drive belt deflection is abovespecification, the snowmobile will bog andlack power at engagement and will have aslower maximum speed. For good perfor-mance, proper belt deflection is critical. Tocorrect this condition, first determine if thedrive belt is within specifications andreplace if worn or too long. Always runthe drive belt in the same direction.Installing the drive belt so the part num-ber can be read will ensure that the drivebelt is always run the same direction.

DRIVE BELT DEFLECTION — Drivebelt length, condition, and deflection areall important for peak performance. Tocheck and adjust drive belt deflection,remove the belt guard; then use the fol-lowing procedure.

NOTE: It may be necessary toremove a shim washer from betweenthe driven clutch sheaves to allowthe driven clutch to close tighter.Adding shim washers will decreasebelt deflection and removing shimwashers will increase belt deflection.Available shim washers from ArcticCat are p/n 0648-714 (0.090 in.) - oneincluded in the tool kit, p/n 0648-715(0.030 in.), and p/n 0648-716 (0.060in.).

NOTE: Removing/adding shimwashers may be done by the snow-mobile owner if qualified to do so. Ifthe owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. This service is at thediscretion and expense of the snow-mobile owner.

1. Turn the engine off; then open theaccess panel.

2. Make sure the drive belt is sitting atthe top of the driven clutch sheaves.

3. Place a straightedge on top of thedrive belt. The straightedge shouldreach from the driven clutch to thetop of the driven clutch.

4. Using a stiff ruler centered betweenthe drive clutch and driven clutch,push down on the drive belt justenough to remove all slack. Note theamount of deflection on the ruler atthe bottom of the straightedge. Thedeflection should be at 1 1/4 in.

0746-092

NOTE: Push down on the belt withthe ruler only until the bottom of thebelt flexes upward; then read theamount of deflection.

5. To correct drive belt deflection,remove the sheave adjuster from theclutch, remove or add shim washersto the adjuster, and install theadjuster.

NOTE: Adding shim washers willdecrease belt deflection; removingshim washers will increase beltdeflection.

6. Install the belt guard; then close theaccess panel.

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DRIVE CLUTCH AND DRIVENCLUTCH — Keeping the drive clutchand driven clutch clean should be the pri-mary consideration of the operator. Thedrive clutch and driven clutch can becleaned of any drive belt accumulationusing compressed air. The sheaves can becleaned using a clean cloth and parts-cleaning solvent.

DRIVE CLUTCH/DRIVEN CLUTCHOFFSET — If premature drive belt wearis experienced or if the drive belt turnsover, offset must be checked. Also, offsetmust be checked whenever either thedrive clutch or driven clutch is serviced.

NOTE: For checking offset, it isnecessary to use Clutch AlignmentBar (p/n 0644-428) to obtain a driveclutch/driven clutch offset of 1.485in. This special tool can be pur-chased from an authorized ArcticCat snowmobile dealer.

To check offset, use the following proce-dure.

1. Open the left-side access panel; thenremove the belt guard.

2. Install the clutch alignment barbetween the drive clutch sheaves.

3. Allow the bar to rest on the driveclutch shaft and against the outsideedge of the driven clutch stationarysheave.

NOTE: The alignment bar mustextend beyond the front edge of thedrive clutch.

4. With the bar against the outside edgeof the driven clutch stationarysheave at points A and B, the barshould just clear the inside edge ofthe stationary sheave of the driveclutch and rest on the stationaryshaft at point C with a maximum 1.5mm (0.060 in.) clearance at point C.At this point, measurement betweenpoints A and C should be 1.485 in.(with a maximum 1.5 mm (0.060in.) clearance). If the bar either willnot clear the inside edge or clearanceis more than the specified amount,the offset must be corrected.

SNO-275A

NOTE: If the offset is out of speci-fication, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for drive system evaluationand/or servicing. This service is atthe discretion and expense of thesnowmobile owner.

GASOLINE — On the 9000 for opti-mum performance, use 91 octane (mini-mum) gasoline.

53

Preparation for StoragePrior to storing the snowmobile, it must beproperly serviced to prevent corrosion andcomponent deterioration. An authorizedArctic Cat Snowmobile dealer should per-form this service; however, the owner/operator can perform this service ifdesired. This service is at the discretionand expense of the snowmobile owner. Toprepare the snowmobile for storage, ArcticCat recommends the following procedure:

1. Clean the seat cushion with a dampcloth and a Vinyl Protectant.

2. Clean the snowmobile thoroughly byhosing dirt, oil, grass, and other foreignmatter from the skid frame, tunnel,hood, and belly pan. Allow the snow-mobile to dry thoroughly. DO NOT getwater into any part of the engine.

3. Change the engine oil and replacethe air filter if necessary.

4. Plug the exhaust system outlet witha clean cloth.

5. Fill the gas tank to its rated capacity;then add Arctic Cat Fuel Stabilizer(p/n 0436-907) to the gas tank fol-lowing directions on the containerfor the stabilizer/gasoline ratio.Tighten the gas tank cap securely.

6. With the snowmobile level, checkthe lubricant level in the chain case.If low, add chain lube through thefill plug hole.

7. Remove the drive belt from the driveclutch/driven clutch. Lay the belt ona flat surface or slide it into a card-board sleeve to prevent warping ordistortion during storage.

8. Clean and inspect the drive clutchand driven clutch.

9. Apply light oil to the upper steeringpost bushing and shafts of the shockabsorbers.

10. Lubricate the rear suspension withall-temperature grease.

11. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely. Make sure all rivets hold-ing the components together aretight. Replace all loose rivets.

12. Clean and polish the hood, console,and chassis with Cat Cleaner (p/n4639-371). DO NOT USE SOL-VENTS. THE PROPELLANTWILL DAMAGE THE FINISH.

NOTE: Disconnect the batterycables making sure to disconnect thenegative cable first; then clean thebattery posts and cables. Charge thebattery.

13. If possible, store the snowmobileindoors. Raise the track off the floorby blocking up the back end makingsure the snowmobile is secure.Loosen the track adjusting bolts toreduce track tension. Cover thesnowmobile with a machine cover ora heavy tarpaulin to protect it fromdirt and dust.

14. If the snowmobile must be stored out-doors, position the snowmobile out ofdirect sunlight; then block the entiresnowmobile off the ground makingsure the snowmobile is secure. Loosenthe track adjusting bolts to reducetrack tension. Cover with a machinecover or a heavy tarpaulin to protect itfrom dirt, dust, and rain.

CAUTIONSealed batteries require charging ifleft for extended non-start periods.Arctic Cat recommends trickle charg-ing once a month. Follow the manu-facturer’s instructions and cautions.

CAUTIONAvoid storing in direct sunlight andusing a plastic cover as moisturemay collect on the snowmobile caus-ing corrosion.

54

Preparation after StorageTaking the snowmobile out of storageand correctly preparing it for another sea-son will assure many miles and hours oftrouble-free snowmobiling. Arctic Catrecommends the following procedure:

1. Clean the snowmobile thoroughly.Polish the exterior of the snowmobile.

2. Clean the engine. Remove the clothfrom the exhaust system. Checkexhaust system and air-intakesilencer for obstructions.

3. Inspect all control wires and cablesfor signs of wear or fraying. Replaceif necessary. Use cable ties or tape toroute wires and cables away fromhot or rotating parts.

4. Inspect the drive belt for cracks andtears. Check belt specifications.Replace if damaged or worn. Installthe drive belt.

NOTE: If the old belt is worn but inreasonable condition, retain it withthe snowmobile as a spare in case ofemergency.

5. Inspect all fuel hoses and oil hosesfor deterioration or cracks; replace ifnecessary. Make sure all connectionsare tight.

6. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely.

7. If not done during preparation forstorage, lubricate the rear suspen-sion with all-temperature grease.

8. Check the coolant level and all cool-ant hoses and connections for deteri-oration or cracks. Add properlymixed coolant as necessary.

9. Charge the battery until fullycharged; then connect the batterycables making sure to connect thepositive cable first. Test the electricstart system.

10. Inspect the entire brake system, allcontrols, headlight, taillight, brake-light, ski wear bars, and headlightaim; adjust or replace as necessary.

11. Adjust the track to the proper tensionand alignment.

55

U.S. EPA Emission Control Statement/Warranty Coverage (U.S. Only)

STATEMENT/WARRANTYArctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA EmissionControl Regulations. Please read the following information completely.

Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-relatedcomponent at no cost to you during the warranty period. You may have non-warranty service performedby any repair establishment that uses equivalent components. The regulations provide significant civilpenalties for tampering that causes your snowmobile to no longer meet U.S. EPA emission standards.

Arctic Cat further warrants that the engine and its emission-related components are free from defects inmaterials or workmanship that could cause the engine to fail to comply with applicable regulationsduring the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contactyour local authorized Arctic Cat snowmobile dealer.

WARRANTY PERIODThe emission warranty period for this snowmobile begins on the same date as the standard warrantycoverage and continues for 30 months or 2500 miles, whichever comes first.

COMPONENTS COVEREDThe emissions warranty covers major emissions control components and emission-related componentslisted as follows:

Engine Management and Sensors Fuel/Air SystemBarometric Pressure Sensor Fuel InjectorsCamshaft Position Sensor Fuel Pressure RegulatorEngine Control Module (ECM) Fuel PumpEngine Coolant Temperature Sensor Carburetor(s)Intake Air Temperature Sensor Turbocharger AssemblyManifold Absolute Pressure Sensor Air Bypass ValveOxygen Sensor Turbo Waste Gate Control ValveThrottle Position Sensor Crankcase Ventilation System

ISC Valve

Ignition System Miscellaneous Items Used in Aforementioned SystemsIgnition Coil ConnectorsKnock Sensor System SwitchesCrankshaft Position Sensor GrommetsExhaust Temperature Sensor ClampsCapacitive Discharge Ignition (CDI) Module HosesMagneto Pick-Up TiesSpark Plugs Gaskets

Wiring

OWNER'S RESPONSIBILITIESThe owner of any snowmobile warranted under this Arctic Cat Emission Control Statement isresponsible for the proper maintenance and use of the snowmobile in accordance with Arctic Cat’srecommendations in the Operator's Manual.

56

NOTES

57

Change of Address, Ownership, or Warranty Transfer

Arctic Cat Inc. keeps on file the current name and address of theowner of this vehicle. This allows Arctic Cat to reach the currentowner with any important safety information which may benecessary to protect customers from personal injury or propertydamage. Please make sure a copy of this form is completed andreturned to Arctic Cat Inc. if you move or if the vehicle is sold toanother party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty,fill out this form completely; then return a copy of this form toArctic Cat Inc. Arctic Cat will then process the application andissue warranty for the balance of the time remaining of theoriginal warranty. Warranty coverage is only available in thecountry in which the original retail purchase occurs to theoriginal retail purchaser resident in that country or to atransferee resident in that country of the balance of theremaining warranty.

Address Change

Ownership Change

Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name ________________________________________

Address ______________________________________

City/State (Province)/Zip Code (Postal Code) __________

Phone # ( ) __________________________________

Year and Model _________________________________

Vehicle Identification Number (VIN) _________________

Fold Back Once

CHANGE OF ADDRESS/OWNERSHIP

ARCTIC CAT INC.PRODUCT SERVICE AND

WARRANTY DEPT.P.O. BOX 810

THIEF RIVER FALLS, MN 56701

PlaceStampHere

Warranty Procedure/Owner Responsibility

At the time of sale, an Owner Registration form is to be completed by the sellingdealer and consumer. The receipt of the registration form by Arctic Cat is a condi-tion precedent to warranty coverage. It is the selling dealer’s responsibility to retainand/or submit the appropriate copies of the form to the appropriate place(s) to initi-ate warranty coverage.

The dealer will furnish to the consumer a signed copy of the form which must bepresented to the dealer when requesting warranty service. The registration form isthe consumer’s proof of ownership and warranty eligibility. The form is usedby the dealer to validate the warranty claim. Retain your copy of the form andkeep it in a safe place.

When warranty repair is suspected, the snowmobile should be taken to the sellingdealer, who has the primary responsibility to perform warranty repairs. Subject tothe limitations set forth in the Limited Warranty, in the event the selling dealer hasceased to do business, you have moved, or you are in a location away from yourselling dealer, warranty may be performed by any authorized Arctic Cat Snowmo-bile dealer.

The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or partto determine if, in his opinion, a warrantable condition exists. If a warrantable con-dition appears to exist, the dealer will repair or replace, at Arctic Cat’s option, freeof charge, including any related labor costs, all parts that are found to be warrant-able and any other parts which the warrantable part caused to be damaged. You, theconsumer, will then be asked to sign a warranty form to ensure Arctic Cat that thewarranty work was actually performed.

It is the consumer’s responsibility to maintain and service the snowmobile in accor-dance with Arctic Cat’s recommendations in the Operator’s Manual. To protectyourself and your snowmobile, follow all safety and service tips. Arctic Cat willNOT warrant repairs required as a result of not performing standard operatormaintenance, storage procedures, and service as outlined in the Operator’sManual.

Should you have any questions concerning the warranty, contact an authorized Arc-tic Cat Snowmobile dealer.

Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558

Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2260-150Phone: (218) 681-9851 - U.S./(204) 982-1656 - Canada

®TM

Documents

OPERATOR’S MANUAL - Arctic Cat · OPERATOR’S MANUAL ZR 5000/7000/9000 ... The law of the State of ... This Operator’s Manual should be considered a permanent part of the snowmobile