2014 Arctic Cat ZR/XF/M (M8000) Snowmobiles OEM Service & Repair Manual

Arctic Cat ZR/XF/M Snowmobile Service Manual 2014 This manual is comprised of the 2014 Arctic Cat ZR/XF/M 2-stroke manual, the 2014 Arctic Cat ZR/XF/M 4-stroke manual, and the 2014 Arctic Cat ZR120 manual. Use the links below or the bookmarks to the left to get to the manual that covers your model. 2014 Arctic Cat ZR/XF/M 2-stroke service manual 2014 Arctic Cat ZR/XF/M 4-stroke service manual 2014 Arctic Cat ZR120 service manual

[SNOWMOBILE] SERVICE MANUAL 2014 ZR/XF/M 2-STROKE

FOREWORD This Arctic Cat Service Manual contains service and maintenance information for certain Model Year 2014 Arctic Cat Snowmobiles (see cover). The manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given con- dition. The service technician should become familiar with the operation and construction of the components or systems by carefully studying the complete manual. This will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the snowmobile. The symbol  NOTE: identifies supplementary information worthy of particular attention. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc.

1 TABLE OF CONTENTS General Information ...................................................... 2 Snowmobile Identification ................................................. 2 Recommended Gasoline and Oil ...................................... 2 Engine Break-In ................................................................ 2 Drive Belt Break-In ............................................................ 2 Genuine Parts ................................................................... 3 Varying Altitude Operation ................................................ 3 Preparation For Storage.................................................... 4 Preparation After Storage ................................................. 5 After Break-In Checkup/Checklist ..................................... 6 Engine Specifications ........................................................ 6 Crankshaft Runout/Repair Specifications.......................... 7 Arctic Power Valve (APV) System Specifications ............. 7 Electrical Specifications .................................................... 8 Drive System Specifications.............................................. 9 Drive Clutch/Driven Clutch-Related Specifications ........... 9 Drive System Components ............................................... 9 Chain Case Performance Calibrations............................ 10 Track Specifications ......................................................... 11 Suspension Specifications ............................................... 11 Torque Conversions ......................................................... 11 Torque Specifications ...................................................... 12 Steering and Body ...................................................... 13 Steering Post (ZR/XF) ..................................................... 13 Ski ................................................................................... 17 Ski Wear Bar ................................................................... 18 Spindle ............................................................................ 18 Steering Tie Rod ............................................................. 19 Ski Alignment .................................................................. 21 A-Arms ............................................................................ 22 Ski Shock Absorber ........................................................ 23 Sway Bar (ZR/XF) ........................................................... 24 Front Bumper .................................................................. 24 Seat Assembly (ZR/XF/M STD) ...................................... 24 Seat Assembly (M Sno Pro/HCR/LTD) ........................... 25 Taillight/Brakelight Assembly .......................................... 25 Rear Bumper/Snowflap ................................................... 26 Windshield/Console/Headlight ........................................ 26 Headlight Bulb................................................................. 27 Adjusting Headlight Aim ................................................. 27 Engine .......................................................................... 29 Engine Removing/Installing - 6000 ................................. 29 Assembly Schematic - 6000 ........................................... 35 Engine Removing/Installing - 8000 ................................. 37 Assembly Schematic - 8000 ........................................... 43 Engine Servicing - 6000 .................................................. 45 Engine Servicing - 8000 .................................................. 59 Troubleshooting Engine .................................................. 76 Engine-Related Items ................................................. 78 Water Pump (8000) ......................................................... 78 Water Pump (6000) ......................................................... 81 Pressure Testing Engine ................................................. 84 Liquid Cooling System .................................................... 84 Cooling System Schematic ............................................. 85 Recoil Starter .................................................................. 85 Arctic Power Valve (APV) System................................... 87 Exhaust Controlled Timing (ECT) System ...................... 91 Fuel Systems ............................................................... 92 EFI System ...................................................................... 92 Individual Components .................................................... 92 Self-Diagnostic System/Codes (6000) ............................. 95 Self-Diagnostic System/Codes (8000) ............................. 95 Fuel Pressure Regulator .................................................. 96 Throttle Body Assembly................................................... 96 Throttle Cable .................................................................. 97 Fuel Pump ....................................................................... 97 Troubleshooting ............................................................... 99 Oil-Injection Pump (8000) .............................................. 100 Gas Tank ....................................................................... 102 Electrical Systems .................................................... 104 Ignition System .............................................................. 104 Throttle Position Sensor ................................................ 104 Electrical Resistance Tests ............................................ 106 Voltage Regulator Tests ................................................. 110 Testing Oil Level Sensor ................................................ 108 Testing Fuel Gauge Sender ........................................... 109 Emergency Stop Switch................................................. 109 Starter Relay Solenoid ................................................... 109 Fuse............................................................................... 109 Ignition Switch ............................................................... 110 Starter Motor .................................................................. 110 Troubleshooting Electric Start ........................................ 114 Ignition Timing ............................................................... 114 Brakelight Switch ........................................................... 115 Headlight Dimmer Switch .............................................. 115 Testing Handlebar Warmer Elements ........................... 115 Testing Thumb Warmer Element ................................... 116 Testing Handlebar Warmer/Thumb Warmer Switch....... 116 Testing Speedometer Sensor ........................................ 116 Testing Shift Switch ....................................................... 117 Testing Servomotor/Potentiometer ................................ 117 Troubleshooting Servomotor ......................................... 119 Voltage/Resistance Chart - Air Temperature (8000) ...... 121 Voltage/Resistance Chart - Air Temperature (6000) ...... 121 Voltage/Resistance Chart - Coolant Temperature ......... 122 Drive Train/Track/Brake Systems ............................ 123 Drive Belt ....................................................................... 123 Drive Clutch ................................................................... 123 Driven Clutch ................................................................. 125 Drive Clutch/Driven Clutch ............................................ 127 Drive Train ..................................................................... 128 Drive Sprockets ............................................................. 132 Track Tension ................................................................ 135 Track Alignment ............................................................. 135 Brake System ................................................................ 136 Brake Lever/Master Cylinder Assembly ........................ 141 Troubleshooting Hydraulic Brake System...................... 142 Troubleshooting Track ................................................... 143 Troubleshooting Drive Clutch/Driven Clutch .................. 144 Suspension ................................................................ 145 Suspension Setup Basics .............................................. 145 Servicing Suspension .................................................... 150 Rebuilding/Recharging Fox Air Shocks ......................... 164 Servicing Fox Float X EVOL Front Shock Absorbers .... 169 Servicing Mono-Tube Shock Absorbers ........................ 187 Pressurizing Rebuildable Shocks .................................. 192

2 General Information NOTE: General specifications for each 2014 Arctic Cat Snowmobile can be accessed from the Arctic Cat Cat Tracker Dealer Communication System online. NOTE: Some illustrations and photographs used in this section are used for clarity purposes only and are not designed to depict actual conditions. Snowmobile Identification The Arctic Cat Snowmobile has two important identification numbers. The Vehicle Identification Number (VIN) is stamped into the tunnel near the right-side footrest. The decal also dis- plays pertinent production information. The Engine Serial Number (ESN) is stamped into the crankcase of the engine. These numbers are required to complete warranty claims properly. No warranty will be allowed by Arctic Cat if the engine serial number or VIN is removed or mutilated in any way. Recommended Gasoline and Oil RECOMMENDED GASOLINE The recommended gasoline to use in these snowmobiles is 91 octane (minimum). NOTE: If a situation arises in which 91 octane gasoline is not available, 87 octane gasoline can be substi- tuted; however, do not prolong the usage of 87 octane gasoline as it will cause poor engine performance. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol are acceptable gasolines. RECOMMENDED OIL The recommended oil to use in the oil-injection system is either Arctic Cat C-Tec2 for the 6000 or Arctic Cat APV Synthetic 2-Cycle Oil for the 8000. These oils are specially formulated to be used either as an injection oil or as a pre- mix oil (for break-in) and meets all of the lubrication requirements of the Arctic Cat snowmobile engine. Engine Break-In 8000 The Arctic Cat engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 ratio in all oil- injection models. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. 6000 The Arctic Cat engine (when new or rebuilt) requires a short break-in period before the engine is subjected to heavy load conditions. Premixing fuel and oil during the break in period is not required. With the oil delivery control strategy of the electronic oil pump, the pump will automatically compensate and deliver a richer fuel-to-oil ratio during the engine break-in period. Some customers may choose to pre-mix the first tank and if this is the case, a pre-mix ratio of 100:1 is acceptable. A pre-mix ratio of 100:1 combined with the richer fuel/ oil delivered from the electronic oil pump during break- in may cause additional smoke at start up and idle. During the break-in period, a maximum of 1/2 throttle (with varying throttle positions) is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. Drive Belt Break-In Drive belts require a break-in period of approximately 25 miles. Drive the snowmobile for 25 miles at 3/4 throttle or less. By revving the engine up and down (but not exceed- ing 60 mph), the exposed cord on the side of a new belt will be worn down. This will allow the drive belt to gain its optimum flexibility and will extend drive belt life. CAUTION Do not use white gas or gasoline containing methanol. Only Arctic Cat approved gasoline additives should be used. CAUTION Any oil used in place of the recommended oil may cause serious damage. CAUTION Any oil used in place of the recommended oil could cause serious engine damage. CAUTION DO NOT exceed the one (1) tankful limitation of a 100:1 gas/oil break-in mixture. Continuous use of a gas/oil mixture could cause spark plug fouling and excessive carbon buildup. CAUTION DO NOT exceed the one (1) tankful limitation of a 100:1 gas/oil break-in mixture. Continuous use of a gas/oil mixture could cause spark plug fouling and excessive carbon buildup.

3 NOTE: Before starting the snowmobile in extremely cold temperatures, the drive belt should be removed and warmed up to room temperature. Once the drive belt is at room temperature, install the drive belt (see Drive Belt sub-section in the Drive Train/Track/Brake Systems section of this manual). Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit. Varying Altitude Operation Operating a snowmobile at varying altitudes requires recal- ibration of drive system components. Consult the appropri- ate specification sheet on Cat Tracker Online. Following are basic altitude theories for clutching, engine, suspension, and track. CLUTCHING On a normally-aspirated engine as altitude changes, engine horsepower changes with it. As you go up in altitude, the engine loses horsepower. Because of this, the continuously variable transmission (CVT) system needs to be calibrated to compensate for the horsepower loss. At altitudes above 5000 ft, the engine loses peak horsepower but will also lose horsepower at engagement speed. For this reason, calibrating the drive system is usually needed in order to attain acceptable performance. Changing drive clutch engagement speed can be done several ways. Some of the methods will affect other characteristics of CVT operation, so you must be careful what you change. Drive clutch springs are the most common way to increase engagement speed; however, by simply changing the cam arms to a lighter weight from the heavier sea level cam arm, you will gain some engagement speed. Other more complicated methods exist such as engagement notches and changing the position of the cam arm center of gravity in relation to the roller. This is called “tucking the weight” and can be used, but, like the engagement notch, it can hurt belt life. The driven clutch will also play a part in CVT tuning for high altitude operation. A steeper helix (torque bracket) angle in the driven clutch will mean a quicker up-shift. A shallower angle will mean a slower up-shift. If the up-shift is too quick, due to a very steep helix, RPM will be pulled down under the peak operating RPM of the engine (where the horsepower is) and performance will suffer. The engine may even bog. If you have a helix that is too shallow, the engine may over-rev or have poor acceleration. Usually, angles shallower than the sea level calibrations work best. The driven spring will also affect driven clutch tuning. Tighten the spring, and RPM will increase. Loosen the spring, and RPM will decrease. The spring should be used to fine-tune and complement the helix selection. ENGINE A normally aspirated engine will generate more horsepower at sea level than it does at higher altitudes. The reason is that the higher you go, less oxygen is available for the engine to use during its combustion process. Less oxygen means it needs less fuel to obtain the correct air/fuel ratio to operate properly. This is why the fuel ratio has to be recalibrated. High altitude engines operate as though they have a lower compression ratio. This, along with less oxygen and less fuel, means that the engine generates less horsepower. All of these characteristics will become more evident the higher the altitude. SUSPENSION The different riding styles of the individual operator, the varying snow conditions, and the type of terrain are all factors that affect the suspension at high altitude. Trail riding versus powder snow riding versus combination riding will all require different suspension settings. The normal setting for front ski suspension is as little spring pre-load tension as possible for powder snow riding allowing the skis to float across the snow with the least amount of resistance. Trail riding will require more spring tension to carry the varying load more effectively. Many different settings and spring tensions to consider exist when adjusting for riding style and snow conditions. The rear suspension has a number of spring settings that produce different riding characteristics. The front arm spring and shock will also affect the ride and handling when either on a trail or in powder snow. A strong spring setting on this shock will cause the snowmobile to tend to “dig” more when riding in the powder snow rather than climbing up on top of the snow. But, it will work more effectively when riding on a trail. A softer spring setting will allow the front of the rear suspension to collapse much quicker and change the angle of the track to the snow. A more gradual angle will tend to raise the snowmobile up on the snow rather than digging into it. Many possible variables and adjustments to the rear suspension exist depending on snow conditions, riding style, and type of terrain. These adjustments can be made to indi- vidualize the snowmobile to the riding style of the operator. CAUTION Running the engine with the drive belt removed could result in serious engine damage and drive clutch failure.

4 M/XF High Country As snow cover and riding conditions change, several different adjustments can be made to change the ride and handling characteristics for operator preference. Located on the front suspension arm are limiter straps. They limit the amount of “fallout” the front arm can have. These straps may be adjusted in or out due to conditions and riding style. The more the straps are brought up, the more steering power the operator has due to the amount of ski pressure. Another adjustment that can be made on the rear suspension is the front arm shock spring tension. As trail conditions change, the spring pre-load may be used to decrease the chance of the front end “bottoming out.” With a stiffer spring pre-load, the ride of the snowmobile will improve on the trail but will affect the performance in the deep powder snow. In deep powder snow, the stiffer spring pre-load will cause the front-end to “dig” and possibly take longer for it to plane off. Several different-rate springs are available for different riding styles and terrain conditions. On the standard models, the front shock springs are also individually adjustable for the terrain conditions and driving style of the operator. The spring adjuster has been set at the factory so the correct amount of threads are exposed between the spring adjuster and the shock hous- ing as an initial setting. Additional ski pressure can be obtained by tightening the spring tension; ski pressure can be decreased by relaxing spring tension. Springs with different spring rates are available for operator choice and snow conditions. A limit exists as to how far you can pre-load the springs before “coil bind” takes effect where the wire on the spring actually runs into itself and causes binding. Equal adjustments should be maintained on both sides of the snowmobile. On the Sno Pro models with air shocks, they are individually adjustable for the terrain conditions and driving style of the operator. The shocks are preset at the factory (see chart) as an initial setting; however, it is possible to “fine tune” the shocks to match the operator’s weight, riding style, and terrain conditions. Checking and adjusting air pressure must be done at riding temperature (outside). Also, it is advisable to check air pressure when the outside temperature varies more than 25°. NOTE: Care should be taken to have equal pressure in the ski shocks before operating the snowmobile. Finally, track tension should be looked at to make sure that it is within recommended specifications to affect the efficiency of the snowmobile. On models with the torque sensing link, the track is actually tightening as the suspension moves through its range of motion causing the track to sag in the middle and rub on the top part of the rear suspension arm. Track Carefully matching the riding requirements to the type of track will ensure the maximum use of all available engine power. Lug height and track durometer are the two main concerns when selecting a track for various riding styles. Tracks exist with lug heights from 0.750” up to 2.6” to accommodate various snow conditions. Generally, the deeper the snow, the taller the lug. It must be noted that the installation of any deep-lug track may reduce top end speed and promote premature wear strip wear in marginal snow conditions. Durometer is a measurement of how hard a rubber is. The lugs on most tracks range between 60 and 85 durometer. On the durometer scale, the higher the number, the harder the lugs. For riding in deep powder snow, a softer durometer track works best. The softer rubber allows the track to “give” a little and pack the snow creating lift rather than digging its way straight down. When hill-climbing, the harder lug of an 80 durometer track works the best due to penetrating the hard snow creating more bite. Some tracks come with a dual durometer rating, such as a track with a 80/60 durometer rating. The lugs on this track are 80% 80 durometer rubber, and the top 20% is made of the softer 60 durometer rubber. This track is designed to be a good all-around track for riding mostly in deep powder snow but can climb the occasional hard snow hill. Preparation For Storage Prior to storing the snowmobile, it must be properly ser- viced to prevent corrosion and component deterioration. 1. Clean the seat cushion with a damp cloth and Arctic Cat Vinyl Protectant. 2. Clean the snowmobile thoroughly by hosing dirt, oil, grass, and other foreign matter from the skid frame, tunnel, hood, and belly pan. Allow the snowmobile to dry thoroughly. DO NOT get water into any part of the engine. 3. Place the rear of the snowmobile up on a shielded safety stand; then start the engine and allow to idle. Spray an Engine Storage Preserver into the intakes until the engine exhaust starts to smoke heavily or until the engine starts to drop in RPM. Turn engine off. Install the intake boots. 4. Plug the exhaust system outlet with a clean cloth. 5. With the ignition switch in the OFF position: A. Disconnect the high tension leads from the spark plugs; then remove the plugs, connect them to the leads, and ground them on the cylinder heads. Initial Setting Chart Model Front Shock (Ski) Rear Arm Shock ZR Sno Pro 5.3 kg/cm 2 (75 psi) N/A M Sno Pro 6.3 kg/cm 2 (90 psi) 10.2-10.6 kg/cm 2 (145-150 psi) XF Cross Country 5.3 kg/cm 2 (75 psi) 10.19 kg/cm 2 (145 psi) XF Cross-Tour N/A 10.19 kg/cm 2 (145 psi) RR 250 psi (nitrogen) 25/225 psi (air) 250 psi (nitrogen) CAUTION Do not run the engine without the belt guard in place and secured. CAUTION Never crank the engine over without grounding the spark plugs. Damage to coils and/or ECM may result.

5 B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum- based oil into each spark plug hole and pull the recoil starter handle slowly about 10 times. C. Install the spark plugs and connect the high tension leads. 6. Fill the gas tank to its rated capacity; then add Arctic Cat Fuel Stabilizer to the gas tank following direc- tions on the container for the stabilizer/gasoline ratio. Tighten the gas tank cap securely. 7. With the snowmobile level, check the lubricant level in the chain case. If low, add chain lube through the fill plug hole. 8. Remove the drive belt from the drive clutch/driven clutch (see the Drive Train/Track/Brake Systems section). Lay the belt on a flat surface or slide it into a cardboard sleeve to prevent warping or distortion during storage; then clean and inspect the drive clutch and driven clutch. 9. Apply light oil to the upper steering post bushings and to the shafts of the shock absorbers; then lubricate the rear suspension with an all-temperature grease. 10. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tight- ened to specifications. Make sure all rivets holding the components together are tight. Replace all loose rivets. 11. Clean and polish the hood, console, and chassis with Cat Cleaner. DO NOT USE SOLVENTS. THE PRO- PELLENT WILL DAMAGE THE FINISH. 12. On electric start models, disconnect the battery cables making sure to disconnect the negative cable first; then clean the battery posts and cables. 13. If possible, store the snowmobile indoors. Raise the track off the floor by blocking up the back end making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover the snowmobile with a machine cover or a heavy, ventilated tarpaulin to protect it from dirt and dust. 14. If the snowmobile must be stored outdoors, position the snowmobile out of direct sunlight; then block the entire snowmobile off the ground making sure the snowmobile is secure. Loosen the track adjusting bolts to reduce track tension. Cover with a machine cover or a heavy, ventilated tarpaulin to protect it from dirt, dust, and rain. Preparation After Storage Taking the snowmobile out of storage and correctly pre- paring it for another season will assure many miles and hours of trouble-free snowmobiling. Arctic Cat recommends the following procedure: 1. Clean the snowmobile thoroughly. Polish the exterior of the snowmobile. 2. Clean the engine. Remove the cloth from the exhaust system. Check exhaust system and air silencer for obstructions. 3. Inspect all control wires and cables for signs of wear or fraying. Replace if necessary. Use cable ties or tape to route wires and cables away from hot or rotating parts. 4. Inspect the drive belt for cracks and tears. Check belt specifications. Replace if damaged or worn. Install the drive belt (see the Drive Train/Track/Brake Sys- tems section). NOTE: If the old belt is worn but in reasonable con- dition, retain it with the snowmobile as a spare in case of emergency. 5. Adjust the throttle cable. Inspect all fuel hoses and oil hoses for deterioration or cracks; replace if necessary. Make sure all connections are tight. 6. Fill the oil-injection reservoir with the recommended 2-cycle oil; then inspect each spark plug. Replace, gap, or clean as necessary. NOTE: After prolonged storage on the 8000, Arctic Cat recommends one tankful of 100:1 gas/oil mixture be used in conjunction with the oil-injection system to ensure proper lubrication. 7. Tighten all nuts, bolts, and cap screws making sure all calibrated nuts, bolts, and cap screws are tight- ened to specifications. 8. If not done during preparation for storage, lubricate the rear suspension with an all-temperature grease. 9. Check the coolant level and all coolant hoses and connections for deterioration or cracks. Add properly mixed coolant as necessary. 10. On electric start models, charge the battery; then connect the battery cables making sure to connect the positive cable first. Test the electric start system. 11. Inspect the entire brake system, all controls, headlight, taillight, brake light, ski wear bars, and headlight aim; adjust or replace as necessary. 12. Adjust the track to the proper tension and alignment. CAUTION Sealed batteries require charging if left for extended non-start periods. Arctic Cat recommends trickle charging once a month. Follow the manufacturer’s instructions and cautions. CAUTION Avoid storing in direct sunlight and using a plastic cover as moisture may collect on the snowmobile causing corrosion.

6 After Break-In Checkup/ Checklist Certain areas require adjustment after the break-in period in order to obtain peak performance. These areas are the following. DRIVE BELT DEFLECTION — Drive belt deflection is very important to the snowmobile. Even if it is checked and is correct when the snowmobile is set up, it does change (more so during the break-in period). This is because the rubber engine mounts and the rubber snubber on the torque link will all take a “set” during the first 100 miles allowing the distance between the drive clutch and driven clutch to shorten. When this happens, the snowmobile will appear to have too long of a drive belt. To add to this, the drive belt wears and stretches. This sometimes leads to a reduction in low-end performance, and if not corrected, can cause premature drive belt wear. After the break-in period, drive belt deflection should be checked according to the instructions given in the Drive Train/Track/Brake Systems section of this manual. DRIVE CLUTCH/DRIVEN CLUTCH ALIGNMENT (OFFSET) — The alignment between the drive clutch and driven clutch are set at the factory. Nor- mally, no adjustment is necessary; however, if premature drive belt wear or poor performance is experienced, the drive clutch/driven clutch alignment must be checked. See “Checking Offset” in the driven train section in this manual. TRACK TENSION AND ALIGNMENT — A certain amount of stretch occurs on all tracks during the first 500 miles. The track must be inspected/adjusted after the first 50 to 100 miles to the specifications given in the Track Specifications sub-section of this section and periodically thereafter. If these adjustments aren’t performed, the track may “derail” which leads to track and slide rail damage. Along with these major areas, other areas should be checked and adjusted. Below is a list of items to check after the break-in period. The recommended mileage for this inspection is between 100 and 300 miles.  Check drive belt deflection - drive clutch/driven clutch alignment  Adjust track tension and alignment  Check throttle cable tension  Check oil-injection pump adjustment  Check engine idle  Check coolant level  Check chain case lubricant level  Check lights (high/low beam, brakelight)  Check safety switch operation  Check engine compartment for any rubbing components  Check steering hardware for tightness  Check skid frame and A-arm mounting hardware for tightness  Check brake lever travel and adjustment  Grease all lubrication points Engine Specifications 6000 8000 ITEM Engine Number 0962-011 Displacement 599 cc Bore x Stroke 73.8 x 70 mm Compression Ratio 6.62:1 Cooling System Liquid Ignition Timing (Engine Warm) 16.5° @ 2000 RPM 0.072” Spark Plug (NGK) BPR9ES Spark Plug Gap 0.028-0.031” Piston Skirt/Cylinder Clearance 0.0041-0.0053” Piston Ring End Gap 0.012-0.0196” Cylinder Trueness Limit 0.004” Piston Pin Diameter 0.8659-0.8661” Piston Pin Bore Diameter 0.8661-0.8665” Connecting Rod Small End Bore 1.0631-1.0634” Connecting Rod Radial Play 0.0001-0.0008” Crankshaft Runout (t.i.r.) 0.002” Crankshaft End Play 0.002-0.004” Reed Stopper Height 0.512” ITEM Engine Model Number AB80L4 Displacement 794 cc Bore x Stroke 85 x 70 Compression Ratio 6.62:1 Cooling System Liquid Ignition Timing (Engine Warm) 16.5° @ 2000 RPM 0.072” Spark Plug (NGK) BR9EYA Spark Plug Gap 0.028-0.031” Piston Skirt/Cylinder Clearance 0.0041-0.0053” Piston Ring End Gap 0.012-0.0196” Cylinder Trueness Limit 0.004” Piston Pin Diameter 0.8659-0.8661” Piston Pin Bore Diameter 0.8661-0.8665” Connecting Rod Small End Bore 1.0631-1.0634” Connecting Rod Radial Play 0.0001-0.0008” Crankshaft Runout (t.i.r.) 0.002” Crankshaft End Play 0.002-0.004” Reed Stopper Height 0.512”

2014 Arctic Cat ZR/XF/M (M8000) Snowmobiles OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed