ZR 6000/7000XF 7000M 6000

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 ......................................4-19Snowmobile Identification.................................. 4Control Locations .............................................. 4Gasoline-Oil....................................................... 5Engine Break-In................................................. 6Drive Belt Break-In ............................................ 6Cold Drive-Away Function ................................. 6Speedometer/Tachometer/Deluxe Digital Gauge....................................... 7

Diagnostic Codes .............................................. 8Handlebar Tilt (ZR/XF) .................................... 10Handlebar Height/Tilt (M) ................................ 10Exhaust System .............................................. 11Air-Intake Silencer ........................................... 11Cooling System ............................................... 11Battery (Electric Start) ..................................... 11Jump-Starting .................................................. 11Drive Clutch and Driven Clutch ....................... 12Drive Clutch/Driven Clutch Alignment ............. 13Fuel Pump ....................................................... 13Shock Absorbers (Rebuildable Gas) ............... 13Standard Track (ZR/XF)................................... 13Paddle Track (M) ............................................. 14Track Studs...................................................... 14Reverse Operation .......................................... 15Access Panel/Hood (Removing/Installing) ...... 17Removable Seat (ZR/XF) ................................ 17Removable Seat (M)........................................ 18Towing ............................................................. 18Arctic Power Valve (APV) System (6000)........ 18Exhaust Controlled Timing (ECT) System (6000) ............................................... 19

Operating Instructions .................................20-24Starting and Stopping Engine ......................... 20

Braking ............................................................21Emergency Stopping .......................................22Throttle/Ignition Monitor Switch .......................22Varying Altitude Operation...............................23

Lubrication.................................................. 25-26Chain Case......................................................25Rear Suspension .............................................26

Maintenance............................................... 27-50Periodic Maintenance Checklist.......................27Fuel System.....................................................28Checking Engine Oil (6000).............................29Checking Engine Oil Level (7000) ...................29Coolant Level...................................................31Spark Plugs .....................................................32Checking/Adjusting Valve Clearance (7000) ...33Checking/Adjusting APV Cables (6000) ..........33Battery (Electric Start) .....................................34Fuses...............................................................36Brake System ..................................................37Burnishing Brake Pads ....................................40Drive Belt .........................................................41Track Tension...................................................42Track Alignment ...............................................43Suspension......................................................45Lights ...............................................................47Ski Wear Bars..................................................49Adjusting Ski Stance........................................49Rail Wear Strips...............................................50

Performance Tips ....................................... 51-52Preparation for Storage .............................. 53-54Preparation after Storage .................................55U.S. EPA Emission Control Statement/Warranty

Coverage (U.S. Only) ....................................56Change 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.

1

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.© 2013 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

S2014XFULXUSB S2014XFUSPUSG S2014X7UCTUSB S2014ZRULXUSBS2014XFULEOSW S2014XFUSPUSO S2014X7UCTUSO S2014ZRULEOSOS2014XFULEOSO S2014X7UCCOSB S2014ZRDEEOSG S2014ZRULEOSWS2014XFULEUSW S2014X7UCCUSB S2014ZRDEEUSG S2014ZRULEUSOS2014XFULEUSO S2014X7UCTOSB S2014ZRDEPOSG S2014ZRULEUSWS2014XFUSPOSO S2014X7UCTOSO S2014ZRDEPUSG S2014ZRUEPOSOS2014ZRUEPUSG S2014ZRUEPUSO

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

4

General InformationSnowmobile IdentificationThe Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identification Number (VIN) isstamped into the tunnel near the right-side footrest and on a decal beneath theseat. The decal (on top of the tunnel) alsodisplays pertinent production informa-tion. The Engine Serial Number (ESN) isstamped into the crankcase 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.

ZR/XF

0745-842

M

747-615A

5

RR

0746-789

Gasoline-OilRecommended Gasoline

6000

The recommended gasoline to use in thissnowmobile is minimum 91 octane gaso-line with a maximum 10% ethanol content.

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

Gasolines containing more than 10% eth-anol are not acceptable gasoline for usein this snowmobile. Do not use gasolinescontaining methanol.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 Injection Oil (6000)

The recommended oil to use in the oil-injection system is Arctic Cat C-TEC2Synthetic 2-Cycle Oil (p/n 6639-520 - 48oz) This oil is specially formulated to beused and meets all of the lubricationrequirements of the Arctic Cat C-TEC2snowmobile engine.

Recommended Engine Oil (7000)

The recommended oil to use is SyntheticC-TEC4 Oil (p/n 6639-529 - gal.).After the engine break-in period, the engineoil should be changed every 2500 milesbefore prolonged storage and the oil filtershould be changed every 12,000 miles.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.

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

CAUTIONIf a situation arises wherein 91 octanenon ethanol or 91 octane with maximum10% ethanol gasoline is not available, 87octane gasoline can be substituted inan emergency; however, the prolongedusage of 87 octane gasoline can causesevere engine damage.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage.

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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.

Engine Break-InThe Arctic Cat engine (when new orrebuilt) requires a short break-in periodbefore the engine is subjected to heavyload conditions.6000

During the break-in period (one tank offuel), a maximum of 1/2 throttle (withvarying throttle positions) is recom-mended; however, brief full-throttle accel-erations and variations in driving speedscontribute to good engine break-in. Premixing fuel and oil during the break inperiod is not required. With the oil deliverycontrol strategy of the electronic oil pump,the pump will automatically compensateand deliver a richer fuel-to-oil ratio duringthe engine break-in period. Some may choose to pre-mix the firsttank and if this is the case, a pre-mix ratioof 100:1 is acceptable. A pre-mix ratio of100:1 combined with the richer fuel/oildelivered from the electronic oil pumpduring break-in may cause additionalsmoke at start up and idle.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.

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 FunctionThere is a �“cold drive-away�” functionincorporated within the ECM.

! 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.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving ofthe engine could result in seriousengine damage and drive clutch fail-ure.

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6000

When cold-starting the engine, the cool-ant temperature warning icon and theLOW TEMP display on the readoutscreen will begin to flash. As the enginewarms, the TEMP display will continueto flash, and the RPM �“limit�” of theengine will increase. When the enginereaches proper operating temperature, thecoolant temperature warning icon and theLOW TEMP display will go out.7000

When cold-starting the engine, the cool-ant temperature warning icon will illumi-nate and the LOW TEMP display on thereadout screen will begin to flash. Withthe engine 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 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 LOW TEMP dis-play will go out.Speedometer/Tachometer/Deluxe Digital Gauge

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) and onthe 7000, the engine will �“surge�” to alertthe operator. If the coolant temperaturerises to a critical point above proper oper-ating temperature, the indicator will ceaseflashing and will remain constantly illumi-nated.

NOTE: On the 7000 if the indicatoris constantly on, the engine will shutoff if vehicle speed is reduced to 1.5km-h (0.9 MPH) or slower.

B. High Beam Indicator

The indicator is on whenever the highbeam mode is selected by the headlightswitch.C. Low Oil Indicator (6000)

The indicator is designed to alert thesnowmobile operator when the oil in theoil injection tank gets below a prescribedlevel. Once the indicator illuminates dur-ing operation of the snowmobile, the oper-ator must periodically monitor the level ofoil in the reservoir and must fill the reser-voir the next time gasoline is added to thegas tank.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.C. Oil Pressure (7000)

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 29).

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.

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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/Exhaust Temperature Display

This bar display shows coolant tempera-ture, battery voltage, intake air tempera-ture, and on the 6000, exhausttemperature. Press the Lower Left Buttonto change 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.

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 charts for diagnos-tic codes.

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6000 7000

Code TroubleP0112 Intake air temp sensor 1 circuit low.P0113 Intake air temp sensor 1 circuit highP0117 Coolant temp sensor 1 circuit low.P0118 Coolant temp sensor 1 circuit high.P0122 Throttle position sensor circuit low.P0123 Throttle position sensor circuit high.P0261 Cylinder 1 injector circuit low.P0264 Cylinder 2 injector circuit low.P0324 Knock control system error.P0327 Knock control 1 circuit low.P0328 Knock control 2 circuit high.P0351 Ignition coil (A) primary/secondary.P0352 Ignition coil (B) primary/secondary.P0545 Exhaust temp sensor circuit low.P0546 Exhaust temp sensor circuit high.P1000 Oil pump flow not programmed.P1001 Injector 1 offset not programmed.P1002 Injector 2 offset not programmed.P1003 Oil pump outlier.P1004 ISC outlier.P1005 Regulator voltage circuit low.P1006 Regulator voltage circuit high.P1007 Fuel pump circuit low.P1008 Fuel pump circuit high.P1009 Speed sensor malfunction.P1261 Injector circuit/open - Cylinder 1b.P1264 Injector circuit/open - Cylinder 2b.P1329 Knock sensor loose detection.P1636 Crank angle sensor circuit.P1639 Exhaust valve position sensor circuit

low.P1640 Exhaust valve position sensor circuit

high.P1645 Exhaust valve system malfunction.P1646 Exhaust valve actuator self-cleaning

open error.P1647 Exhaust valve actuator short error.P1755 Engine RPM sensor circuit malfunc-

tion.P2228 Barometric pressor sensor (A) circuit

low.P2229 Barometric pressure sensor (A) cir-

cuit high.P3001 Control module improper shutdown.U1000 Vehicle not registered or invalid PIN

entered.U1001 Vehicle not registered and vehicle lim-

its enabled.U0155 Lost communication with the ECM

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 richP0201 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

high

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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.

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.

Handlebar Height/Tilt (M)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.

P2300 Ignition coil A primary control circuit low

P2303 Ignition coil B primary control circuit low

P2306 Ignition coil C primary control circuit low

U1000 Vehicle not registered or invalid PINU1001 Vehicle not registered and vehicle lim-

its enabledU0155 Lost communication with the ECM

! 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.

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.

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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, use anethylene glycol-based coolant/water mix-ture which will satisfy the coldest antici-pated weather conditions of your area inaccordance with the coolant manufac-turer�’s recommendations.

NOTE: If operating on low snow,ice, or hard-packed snow conditions,it is recommended that Ice Scratch-ers (p/n 5639-897) be installed andused to reduce wear strip wear andengine overheating.

For checking/filling cooling system, referto Coolant Level sub-section in the Main-tenance section.

Battery (Electric Start)It is extremely important that the batterybe maintained at full charge at all timesand that the battery connections be cleanand tight. If charging the battery becomesnecessary, refer to Battery sub-section inthe Maintenance section.

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.

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

CAUTIONOn the 7000, always turn the ignitionswitch key to the OFF position whenthe snowmobile is not being used.Leaving the ignition switch in the ONposition will result in discharging thebattery and possible damage to thebattery.

! 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.

12

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.

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.

! 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.

! 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.

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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 clutchand driven clutch is set at the factory.Normally, no adjustment is necessary aslong as neither the drive clutch nor thedriven clutch is removed or disassem-bled. However, if premature drive beltwear is experienced or if the drive beltturns over, the drive clutch/driven clutchalignment must be checked. Take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service. If notunder warranty, this service is at the dis-cretion 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, cracks orbreaks in the body/reservoir, or a bent shaft.If any one of these conditions is detected,replacement or service is necessary. Take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service. If notunder warranty, this service is at the discre-tion and expense of the 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.

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 (ZR/XF)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.

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.

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Paddle Track (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 StudsNOTE: Stud or hooker plate installa-

tion will void track and tunnel warranty.

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.

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.

! 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 on the 6000, install Tunnel Pro-tector Kit (p/n 6639-075).

Stud Template ChartTrack Length p/n

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

! 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.

15

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. Shifting Into Reverse (6000)

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).

1. Always warm up the engine for 2-3minutes prior to shifting into reverse.The reverse function is cancelledwhen engine temperature is below orabove normal operating range.

2. Shift only with the engine at idleRPM and the snowmobile com-pletely stopped. The reverse func-tion will not engage if engine isabove 3000 RPM.

3. If attempting to shift into reverse attoo high engine RPM (above 3000RPM), the reverse function will becancelled and the coolant temperaturewarning icon will flash. This indicatesthe reverse switch button was pressedat too high RPM. The operator mustreduce engine RPM below 3000 andpress the button a second time.

4. 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.

Shifting Into Reverse (7000)

741-438A

1. Shift only with the engine at idleRPM and the snowmobile com-pletely stopped. The reverse func-tion will not engage if engine isabove 2000 RPM.

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

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

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

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Operating in Reverse (6000)

1. When reverse is engaged, a reverseicon will illuminate in the speedom-eter/tachometer and a reverse alarmwill sound.

2. If the throttle lever is compressedbefore complete reverse engage-ment, the engine may shut down.Always wait for the reverse icon toilluminate and the reverse alarm tosound before backing up.

3. The system will not shift until thebutton is released. Also, the reversefunction will cancel if operated inreverse longer than 45 seconds.Whenever the reverse function hasbeen cancelled, the engine must berun in the forward mode for a mini-mum of 60 seconds at 2000 RPMbefore the reverse function can beused again.

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.

Operating in Reverse (7000)

1. When reverse is engaged, a reverseicon will illuminate in the speedom-eter/tachometer and a reverse alarmwill sound.

2. Always wait for the reverse icon toilluminate and the reverse alarm tosound before backing up.

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

4. 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.

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

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

CAUTIONNever pull the recoil starter rope whenthe engine is running or when operat-ing in reverse. Damage to the engineand/or recoil start system will occur.

! 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.

! 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.

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

0746-793

0747-529

1. Remove the hairpin clip from the pinlocated at the front of the accesspanel. Move the panel up and off thepin; then swing the panel all the wayout and unhinge the panel from thelower console.

2. On the M, remove the thumb screwsecuring the front left access panelto the front facia. Move the panel upand off the pin; then swing the panelall the way out and unhinge thepanel from the lower console.

0746-800

3. Remove the torx-head screws secur-ing the hood (located on the undersideof the hood above the front tube of theupper A-arm); then remove the torx-head screws from the top-side of thehood securing the hood to the upperconsole and the torx-head screwsfrom under the nosepiece of the hood.

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.

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.

NOTE: On the 6000, make sure thehood tabs are seated between thethrottle body boot.

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

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,remove the screw from the underside ofthe seat; then lift on the back of the seatand move it up and rearward to remove it.

746-088A

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

6000

7000

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

6000

18

0747-739

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.

746-273

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

Removable Seat (M)To remove the seat, remove both torx-head screws from the side of the seat;then remove the four tabs from the seatbase from the lower console. Pull backand remove the seat cover and foam.

0747-530

To install the seat, use the following pro-cedure:

1. Position the seat foam into the seatcover by first aligning the front ofthe foam with the front of the seatbase/cover; then wrap the rear of theseat base/cover over the rear of theseat foam. Cover the sides of theseat foam with the seat base/coverand secure using the velcro strap.

2. Remove the backing from the instal-lation bag (p/n 1655-841); thenadhere it to the gas tank making surethe bag covers the velcro on the gastank.

SNO-1206

3. Slide the rear of the seat cover withfoam over the rear of the gas tank;then slide the four tabs into the fourholes in the lower console andsecure to the tunnel using two self-tapping screws. Do not over tighten.

NOTE: To ease the installation ofthe seat cover, carefully pry up therear of the gas tank so the seat covercan easily slide around the rear ofthe gas tank.

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.Arctic Power Valve (APV) System (6000)

This RPM controlled servomotor (servo)actuated system adjusts the size of theexhaust ports to provide peak perfor-mance throughout the RPM range.

7000

CAUTIONThe recommended engine oil to useis Arctic Cat C-TEC 2. Any substitutemay cause an APV malfunction.

19

The system consists of an exhaust valveassembly mounted to the exhaust side ofeach cylinder and connected by adjust-able cables to an electronic servomounted beneath the hood.

0747-751

At low RPM, the exhaust valves are heldin the DOWN position by return springs.This gives the engine a �“low port�”exhaust design calibrated to providemaximum low RPM power and improvefuel economy at trail speeds.At high RPM, the exhaust valves areraised. This creates a �“high port�” exhaustdesign calibrated to provide maximumperformance at high RPM.

NOTE: The RPM ranges will varyfrom model to model.

NOTE: If the servomotor cyclesthree times and then shuts down, theexhaust valve cables are notadjusted correctly. The exhaustvalves may also be sticking.

NOTE: APV cleaning may be doneby the snowmobile owner if qualifiedto do so. If the owner does not feelqualified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. This serviceis at the discretion and expense ofthe snowmobile owner.

Exhaust Controlled Timing (ECT) System (6000)This system automatically adjusts theignition timing to provide maximum per-formance through a variety of operatingconditions. The ECM receives input onengine RPM (demand) and exhaust pipetemperature (engine condition) andadjusts the ignition timing accordingly.This system is not adjustable and is main-tenance free. If a system fault is suspected, use an ohm-meter to check continuity of the exhaustpipe temperature sensor located in theexpansion chamber. A reading of either 0ohm or infinity indicates a failed sensor.

NOTE: A disabled ECT systemWILL NOT cause engine damage;however, a failed ECT system willhave slower throttle response andmay produce slightly less top-endperformance.

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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 sys-tem by compressing the brake lever.The brake lever must feel firm whencompressed; then while holding thebrake lever in the compressed posi-tion, measure the distance betweenthe brake lever and the handlebar.The distance must be greater than2.54 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.

NOTE: On the 6000 when a coldengine is being started, DO NOTCOMPRESS THE THROTTLE CON-TROL LEVER. If the throttle controllever is compressed, the engine willnot start because the fuel/air mixturewill be too lean.

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.

21

7. On models with manual start, pullthe recoil handle slowly until resis-tance is felt; then give a short quickpull. Repeat until the engine starts.

NOTE: In extremely cold weather, pullthe recoil handle slowly two to threetimes to begin the starting procedure.

NOTE: On electric start models, rotatethe key to the START position; thenwhen the engine starts, release the key.

NOTE: When the engine starts,allow it to warm up properly. Idle theengine several minutes until theengine has reached normal operatingtemperature. Do not idle the enginefor excessively long periods of time.

8. There is a �“cold drive-away�” functionincorporated within the engine. Thisfunction is active until the enginereaches operating temperature.

9. Flooding �— If the engine does notstart but seems ready to start, engagethe brake lever lock; then compressthe throttle control lever fully and tryto start the engine. When the enginestarts, release the throttle control leverimmediately. After the warm-up,release the brake lever lock.

NOTE: On the 6000 if the enginefails to start during the attempt withthe throttle control lever com-pressed, remove the spark plugs andclean and dry them thoroughly orinstall a new set of properly gapped,recommended spark plugs.

10. 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.

CAUTIONTo avoid damaging the recoil starter,DO NOT pull the recoil rope to its limitor release the recoil handle from anextended position. Allow the rope torewind slowly.

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

CAUTIONOn the 6000, it is extremely importantthat the engine is properly warmedup before subjecting the engine tohigh speed operation or heavy loads.The engine should be allowed to idleat least 3-4 minutes before it is oper-ated at more than 1/2 throttle. Inextremely cold conditions, the warm-up time will be longer. Cold seizureand piston scuffing caused by insuffi-cient warm-up will not be covered bywarranty. Also, do not idle the enginefor excessively long periods of time.

CAUTIONOn the 7000, always turn the ignitionswitch key to the OFF position when thesnowmobile is not being used. Leavingthe ignition switch in the ON positionwill result in discharging the battery andpossible damage to the battery.

22

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.

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.

! 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.

! 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 cir-

cuitThrottle/Ignition Moni-

tor Switchinterrupts ignition cir-

cuitIgnition Switch interrupts ignition cir-

cuitBrake slows the drive system

Tether (RR) interrupts ignition cir-cuit

23

If the snowmobile engine stops abruptlywhen the throttle control lever is releasedand the activation of the monitor switchis suspected, use the following proce-dure:

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.

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/electricalfeatures (ignition switch, emergencystop switch, headlight, taillight, andbrakelight) will operate properly.

Varying Altitude OperationOperating a snowmobile at varying alti-tudes requires changes in performancecomponents. These changes affect drivetrain components.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.

! 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.

! 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.

24

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

25

LubricationChain Case

NOTE: 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. On the 6000 if the lube level is low,remove the fill plug from the chaincase; then add the appropriateamount of Arctic Cat SyntheticChain Lube (p/n 6639-539) in thefill hole. Install the plug.

3. On the 7000 if the lube level is low,remove the three screws securing theshift actuator to the chain case, dis-connect the actuator wiring harness,and remove the actuator w/exten-sion; then add appropriate amount ofArctic Cat Synthetic Chain Lube (p/n 6639-539) through the shift actua-tor opening. When the lube is half-way up the sight glass, install theshift actuator w/extension and con-nect the actuator wiring harness.Tighten screws to 36 in.-lb.

0746-804

4. On the 7000, start the engine andverify proper reverse and forwardoperation by shifting in and out ofreverse 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.

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

26

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 105 in.-lb.

XM092

3. On the 6000, pour recommendedchain case lube into the fill hole untilthe lubricant is at least halfway up inthe sight glass; then install the plug.

4. On the 7000, remove the threescrews securing the shift actuator tothe chain case, disconnect the actua-tor wiring harness, and remove theactuator w/extension. Pour recom-mended chain lube through the shiftactuator opening until the lubricantis at least halfway up in the sightglass; then install the shift actuatorw/extension and connect the actua-tor wiring harness.

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

5. Install and secure the exhaust reso-nator.

6. On the 7000, start the engine andverify proper reverse and forwardoperation by shifting in and out ofreverse three times.

Rear SuspensionThis procedure should be done every 40operating hours.

NOTE: Arctic Cat recommends thatArctic Cat All-Temp Grease (p/n 4639-365) be used for this procedure.

NOTE: Illustrated are the generallocations of grease fittings. Actual loca-tions will vary from model to model.

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.

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

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

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.

27

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 11,31 Check for leakage, damage, obstructions, coolant

levelOil-Injection System Daily — Check for leakage, damage, and injection/engine

oil levelEngine Oil (7000) 2500 Mi/

Seasonal30 Change oil and filter

Battery Daily 11,34 Check for proper charge and tight connectionsStop Switch Daily — Check for proper operationHoses Daily — Check for damage, leakage, and wearHeadlight & Taillight/Brakelight Daily 47-48 Check for proper operation and cleanlinessSteering System Daily — Check for proper operation, tightness of bolts,

and bindingThrottle Control System Daily 22 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 11 Check for damage, leakage, and obstructionsNuts, Bolts, Fasteners Weekly — Check tightness Recoil Starter Weekly — Check rope for wear, fraying, and proper operationShock Absorbers Weekly 13,45 Check for fluid leakage and damage and air pres-

sure (Fox Air Shocks)Spark Plugs 3500 Mi 32 Check center electrode insulator color, carbon,

and gapValve Clearance (7000) 25000 Mi/

Seasonal33 Check/adjust

Suspension Weekly 45 Check for damage, loose components, and proper adjustment

Track Tension/Alignment Weekly 42,43 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

APV System Monthly 18 Check/adjust as necessaryChain Case Daily 25 Check lube level and for leakageChain Case - Lubricant Seasonal — ReplaceHeat Exchangers Monthly — Check for wear, leakage, and damageDrive Clutch/Driven Clutch Monthly 12,13 Check for damage, binding, and wear/remove

drive belt, clean drive clutch/driven clutchRear Suspension Monthly 26 Grease

28

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.Fuel System

In-Line Fuel Filter

Arctic Cat recommends that the in-linefuel filter be replaced every 5000 miles.The filter must be clean to allow the fuelhose to transmit the amount of gasolinerequired. 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 6000, the fuel filteris located above the recoil. Toaccess the filter, the access panelsand hood need to be removed.

XM183A

NOTE: On the 7000, the fuel filteris located on top of the fuel tank. Toaccess the filter, the access panels,hood, and console need to beremoved.

XM184

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 thechanging of the fuel filter and theengine is started for the first time,inspect the filter area for any signsof leaks.

! 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.

CAUTIONMake sure the fuel filter is properlyseated into the holder.

29

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 (6000)The 6000 does not have a sight glass on theside of the oil tank for checking the oil level.The oil level may be checked by visuallylooking down into the tank or add oil whenthe oil light turns on display on the gauge.The oil tank (when filled to the bottom ofthe filler neck) will have 3.6 quarts of oil.The oil light will turn on when the oil tankcapacity is down to 1.5 quarts. If the oillevel reaches 0.75 quarts, air can be intro-duced to oil pump cavity during vehicleoperation causing the risk of engine seizure.

SNO-342A

Adding Engine Oil (6000)

1. Park the snowmobile on a level sur-face; then remove the right-sideaccess panel.

2. Remove the fastener securing the rightside of the lower console to the skidplate.

3. Remove the oil tank cap and add theappropriate oil through the fillerneck making sure to fill only to thebottom of the filler neck.

XM185A

Checking Engine Oil Level (7000)

NOTE: 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 sur-face; then start the engine and let itidle and warm up until the fan on theradiator turns on, or if the snowmobilewas operated, allow the engine to idlefor 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

CAUTIONCare must be taken not to over-fill theoil tank.

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.

30

3. If oil is not visible halfway up in thesight glass, add recommendedengine oil until oil is visible half-way up the sight glass.

Changing Engine Oil/Filter (7000)

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

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

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 rear access plate from beneaththe snowmobile.

3. Place a drain pan beneath the engine oildrain screw; then remove the screw andallow the oil to drain completely.

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.

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

6. Install the new oil filter by turning theoil filter by hand until the seal has con-tacted the oil filter mounting surface;then tighten the oil filter to 12 ft-lb.

7. Install the engine oil drain screwTighten the screw to 7.2 ft-lb.

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 reservoir, 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.

10. Pour the recommended engine oilinto the oil tank.

11. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position and theignition switch to the ON position.The Oil Pressure Warning Iconshould 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.

12. If the warning icon illuminates(from step 11), start the engine. Thewarning icon should go out withinfive seconds. If it does, proceed tostep 13.

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

! WARNINGCare must be taken if a hot drain plugis removed by hand. Burning couldoccur.

31

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 12. 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.

13. Once the engine has reached operatingtemperature, shut the engine off; thenadd oil to the oil reservoir until oil isvisible halfway 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.

14. Install the access plate and torx-headscrews beneath the snowmobile; theninstall the hood and access panels.

Coolant LevelNOTE: Use a good quality, ethyl-

ene glycol-based, automotive-typecoolant.

NOTE: Always check the coolantlevel with the engine cold.

6000

Locate the coolant tank behind theexpansion chamber. If the coolant needsto be added, fill the coolant tank up to thecold fill line located on the tank.

747-545A

NOTE: The tabs on the MAG sideof the coolant tank are to hold extraspark plugs.

XM130A

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.

0747-766

CAUTIONAfter operating the snowmobile forthe initial 5-10 minutes, stop theengine, allow the engine to cooldown, and check the coolant level.Add coolant as necessary.

32

Spark Plugs7000

NOTE: 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.

1. Remove the ignition coils from thecylinder head cover.

2. Remove the three spark plugs.NOTE: Prior to installing the spark

plugs, check the gap between theelectrode and ground strap. Theclearance should be 0.028” - 0.031”.

3. Install the spark plugs. Tighten to9.4 ft-lb.

4. Install the ignition coils onto the cyl-inder head cover making sure theyare fully seated.

5. Install the hood and access panels.6000

NOTE: 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.

1. Remove the springs securing theexpansion chamber to the exhaustmanifold and resonator.

2. Move the expansion chamber out ofthe way to access the spark plugs.

3. Remove the spark plug caps fromthe plugs.

4. Using a spark plug wrench, removethe plugs.

5. Install the plugs and finger-tighten.6. Tighten the spark plugs to 19 ft-lb;

then install the spark plug caps.7. Place the expansion chamber into

position and secure to the exhaustmanifold and resonator with thesprings.

8. Install the hood.Checking Spark Plugs (6000)

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

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

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

33

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 oil-injection pump syn-chronization and ignition timing arecorrect, different heat-range sparkplugs may be necessary. AuthorizedArctic Cat Snowmobile dealers havedetailed spark plug information.Consult a dealer before changingspark plugs, as incorrect heat-rangespark plugs could cause poorengine performance or engine dam-age.

Checking/Adjusting Valve Clearance (7000)After 25000 miles, valve clearanceshould be checked and adjusted as neces-sary.

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

Checking/Adjusting APV Cables (6000)Proper cable adjustment is critical to theoperation of the APV system. Althoughinspecting cable adjustment is recommendedevery 1000-2000 miles, the cable should notneed adjustment often. To check the cableadjustment, use the following procedure:

0745-819

1. Using a small needle-nose pliers,remove the servomotor cable holder.

0745-823

2. Using an adjustable wrench, rotatethe servomotor actuator counter-clockwise to loosen the cable; thenpull the cable housings down andout of the servomotor.

NOTE: For installing purposes,note the side that the servomotorcables are installed on.

3. Slide each cable drum out of the slotof the servomotor actuator.

4. While holding the cable housingfirmly, pull the cable as far out as itwill go; then release. Repeat three tofour times. The cable/exhaust valveshould move freely without binding.

CAUTIONIf a spark plug is light gray, white, orblack and another is tan or lightbrown, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

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

CAUTIONDo not use the nut securing theclutch to the servomotor to rotate theactuator.

34

NOTE: If the cable/exhaust valvedoes not move freely, the exhaust valveassembly will need to be removed forfurther inspection. Take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for this service.

NOTE: When measuring the cables,they are to be routed as close to theirinstalled position as possible.

5. While holding the cable housing,lightly pull on one cable end toremove any slack; then measure theamount of exposed cable from thecable housing to the end of the cable(cable drum).

0735-516

NOTE: The two cable measure-ments must be equal in length orless than 0.5 mm (0.020 in.) differ-ence in length from each other.

NOTE: Repeat steps 4 and 5 for eachcable; then compare the measure-ments to the APV Cable Length chart.

NOTE: The measurements must bewithin the specifications from thechart. If the measurements arewithin specifications, no adjustmentis necessary (proceed to step 8). Ifthey are not within specifications,proceed to step 6.

6. Loosen the jam nut on the cable tobe adjusted; then using the adjustingnuts, lengthen or shorten the housingas needed.

7. Once the proper length has beenattained, hold the adjusting nut in placeand tighten the jam nut securely.

8. Place the cable housings into posi-tion in the servomotor. Secure thecable housings with the cable holder.

Battery (Electric Start)These 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:

APV CABLE LENGTH 6000 1.377 in. ± 0.039 in.

CAUTIONAssure the cables are rotated andsecured properly to avoid contactingexhaust components.

! 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.

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

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 the batteryvoltage. The meter must read no lessthan 12.5 DC Volts for a fullycharged 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 battery

charger, always follow the char-ger manufacturer�’s instructions.

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

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.

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)

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 (positiveto positive and negative to negative)for a short period of time with thecharger connected. After 10-15 min-utes, disconnect the booster batteryleaving the charger connected andthe charger should continue tocharge. If the charger “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.

XM127A

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.

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: On the 7000, the fuse blockis behind the coolant overflow bottle.On the 6000, open the right-sideaccess panel; the fuse block is onthe upper spar.

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.

6000

7000

37

XM124A

XM132

NOTE: There are spare fusesbeneath the fuse block cover.

2. Remove the suspected fuse.NOTE: Fuse function descriptions

are 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.

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.

! 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.

7000

6000

! 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.

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

38

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 brake

lever as it will produce an inaccuratereading.

2. Measure the distance between thebrake lever and the handlebar. Thedistance must be greater than 2.54cm (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.

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

XM145A

! 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.

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

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

39

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 reservoircover; then remove most of thebrake fluid from the reservoir. Installthe 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.3. Remove the torx-head screws secur-

ing the brake shield to the belt guardmount; then remove the cap screwssecuring the brake shield to thebrake 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

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.

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

40

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;then secure the pad with the hairpinclip.

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 timesallowing some cooling betweenstops.

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 adjustment

bolt clockwise until it is finger tight;then loosen it 1 1/2 turns.

0747-831

4. While holding the bolt with awrench, 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 is

installed correctly.

! 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

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 ArcticCat Snowmobile dealer, as Arctic Catdrive belts are made to exact specifi-cations and of quality material. Beltsmade by other manufacturers maynot be of the same specifications orquality and, therefore, usage couldresult in poor performance and pre-mature 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.).

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.

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

42

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: 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 (threads coated with blue Loc-tite #243) to 20 ft-lb.

3. Install the left-side access panel.

4. Release the brake lever lock.Track TensionTrack tension is directly related to theoverall performance of the snowmobile.If the track is too loose, it may slapagainst the tunnel causing wear or it may�“ratchet�” on the track drive sprockets. Ifextremely loose, the idler wheels mayclimb over the track lugs forcing thetrack against the tunnel causing the trackto �“lock.�” Arctic Cat recommends thatthe track tension be checked daily duringthe first 300 miles of operation and oncea week thereafter and adjusted accordingto need. The track will stretch and take a�“set�” during break-in. Track deflectionmust be maintained within the recom-mended range.

Checking Track Tension

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

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

! 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.

43

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 down onthe scale to the recommended pressure(see chart). Measure the deflection (dis-tance) between the bottom of the wearstrip and the inside surface of the trackclip. Measurement 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 ten-sion adjustment, perform all adjust-ments on both sides of thesnowmobile.

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.5. After proper track tension is

obtained, 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 Alignment

Proper 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.

Track Tension129” 20 lb

137” 25 lb

141”/153” 12-15 lb

CAUTIONAlways maintain track tension withinrecommended specification.

! 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.

44

Checking Track Alignment

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

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.

0745-811

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

NOTE: Make sure correct tracktension is maintained after adjust-ing track alignment.

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.

! 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.

! 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.

45

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 individ-ually adjustable for the terrain conditionsand driving style 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.Additional ski pressure can be obtainedby tightening the spring tension; ski pres-sure can be decreased by relaxing springtension.

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.

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°.

Initial Setting Chart

Model Front Shock (Ski) Rear Arm Shock

ZR/XF Sno Pro

5.3 kg/cm2

(75 psi)N/A

XF 7000 CC

5.3 kg/cm2

(75 psi)10.2-10.6 kg/cm2

(145-150 psi)

M Sno Pro

6.3 kg/cm2

(90 psi)10.2-10.6 kg/cm2

(145-150 psi)RR 250 psi (nitrogen)

25/225 psi (air)250 psi (nitrogen)

46

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 theshock.

Adjusting Skid Frame Front Arm

The skid frame front arm shock springtension and the limiter straps are adjust-able. However, Arctic Cat recommendsthat the shock spring be maintained at thefactory preset of 1/8-1/4 in. preload.Tightening the skid frame front arm shockspring may cause improper balance andmay ruin the handling features of thesnowmobile.The length adjustment of the front armlimiter straps determines the weight dis-tribution between the front of the skidframe and the skis. Tightening the limiterstrap (shortening the strap) will pull upon the front of the skid frame and willincrease ski pressure. Loosening the lim-iter strap (lengthening the strap) lowersthe front of the skid frame and decreasesski 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.

XF Crosstour 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

Trail @ 20°F140 psi

140 Shop @ 70°F 165 psi

Trail @ 20°F150 psi

180 Shop @ 70°F 170 psi

Trail @ 20°F155 psi

220 Shop @ 70°F 180 psi

Trail @ 20°F160 psi

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

47

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.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

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

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-headscrews.

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).

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 inter-sects the horizontal mark on the aim-ing surface directly in front of theheadlight.

5. Engage the brake lever lock and startthe engine. Move the headlight dim-mer switch to the HIGH beam posi-tion. DO NOT USE LOW BEAM.

6. Observe the headlight beam aim.Proper aim is when the most intensebeam is centered on the vertical mark5 cm (2 in.) below the horizontalmark on the aiming surface.

0745-813

7. Adjust the headlight using theadjusting screw on the backside ofthe headlight using a 4 mm swivelsocket and long extension until cor-rect aim is obtained. Shut the engineoff; then disengage the brake leverlock.

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

49

0746-807

Ski Wear BarsThe ski wear bar is a replaceable barattached to the underside of the ski. Thepurpose of the wear bar is to assist inturning the snowmobile, to minimize skiwear, and to maintain good steering con-trol. If the snowmobile is operated pri-marily in deep snow, ski wear bar wearwill be minimal; however, if the snow-mobile is operated on terrain where thesnow cover is minimal, the ski wear barwill wear faster. To maintain positivesteering characteristics, Arctic Cat rec-ommends that the ski wear bars bechecked before each use and replaced ifworn beyond 1/2 of the original diameter.Ski wear bars are available from anauthorized Arctic Cat Snowmobiledealer.

Removing Ski Wear Bars

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

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.

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.

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

50

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 theslotted nut will be located to theinside of the ski.

6. Apply red Loctite #271 to thethreads of the cap screw; thentighten the nut to 45 ft-lb.

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

8. Repeat procedure for the other ski.Rail Wear StripsArctic Cat recommends that the wearstrips be checked weekly and replaced asnecessary. Measure the wear strips at25.4 cm (10 in.) intervals. Wear stripsmust be 10.7 mm (0.42 in.) thick orthicker.

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. Tem-per the wear strips by driving the snow-mobile for approximately a mile on ahard pack trail; then immediately driveinto deep snow and allow the wear stripsto cool. Repeat the procedure (warmingup the wear strips; then cooling themdown) two or three times.

NOTE: The rail wear strips willwear rapidly if the snowmobile isoperated on terrain on which thesnow cover is minimal. Loose snowis required to cool and lubricate thewear strips and prevent acceleratedwear.

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

NOTE: If operating on ice or hard-packed snow conditions, it is recom-mended that Ice Scratchers (p/n5639-897) be installed to reducewear strip wear and engine overheat-ing.

51

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 theleft access 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.

SNO-276A

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. Close the access 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 andunlock the quarter-turn screw secur-ing console; then move the consoleup and out of the way.

2. Install the clutch Alignment Bar (p/n0644-428) between the drive clutchsheaves.

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 maximum0.76 mm (0.030 in.) clearance atpoint C. At this point, measurementbetween points A and C should be37.72 mm (1.485 in.) with a maxi-mum 0.76 mm (0.030 in.) clearance.If the bar either will not clear theinside edge or is more than the spec-ified amount (see chart), the offsetmust be corrected.

0746-808

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.

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 thoroughlyby hosing dirt, oil, grass, and otherforeign matter from the skid frame,tunnel, hood, and belly pan. Allowthe snowmobile to dry thoroughly.DO NOT get water into any part ofthe engine.

NOTE: On the 7000, change theengine oil if necessary; then proceedto step 6.

3. Place the rear of the snowmobile upon a shielded safety stand.

4. Carefully pry the intake boots partiallyover the throttle body inlets; then startthe engine and allow to idle.

5. Spray an Engine Storage Preserverinto the intakes until the engineexhaust starts to smoke heavily oruntil the engine starts to drop inRPM. Turn engine off. Install theintake boot.

6. Plug the exhaust system outlet witha clean cloth.

7. With the ignition switch in the OFFposition:

A. Disconnect the high tensionleads from the spark plugs; thenremove the plugs, connect themto the leads, and ground them onthe cylinder heads.

B. Pour 29.5 ml (1 fl oz) of SAE#30 petroleum-based oil intoeach spark plug hole and pull therecoil starter handle slowly about10 times.

C. Install the spark plugs and con-nect the high tension leads.

8. 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.

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

10. 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.

11. Clean and inspect the drive clutchand driven clutch.

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

13. Lubricate the rear suspension withall-temperature grease.

14. 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.

CAUTIONDo not run the engine without the beltguard in place and secured.

CAUTIONNever crank the engine over withoutgrounding the spark plugs. Damageto coils and ECM may result.

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15. 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: On electric start models,disconnect the battery cables makingsure to disconnect the negative cablefirst; then clean the battery posts andcables. Charge the battery.

16. 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.

17. 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 using CTEK BatteryMaintainer (p/n 5639-418/419). Followthe manufacturer’s instructions andcautions.

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

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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; then on the 6000, fill theoil-injection reservoir with the rec-ommended 2-cycle oil.

6. On the 6000, inspect the spark plugs.Replace, gap, or clean as necessary.

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

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

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

10. On electric start models, charge thebattery until fully charged; then con-nect the battery cables making sureto connect the positive cable first.Test the electric start system.

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

12. Adjust the track to the proper tensionand alignment.

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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.

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 Snowmobile ______________________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 2259-884Phone: (218) 681-9851 - U.S. (204) 982-1656 - Canada

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