PDF Service Manual 2014 Arctic Cat ZR 120 ATV - 609 KB
This is the official service manual for the 2014 Arctic Cat ZR 120 ATV.
It contains comprehensive instructions for maintenance, troubleshooting, and repair.
With detailed diagrams and specifications, this manual is essential for both DIY enthusiasts and professional mechanics.
Keep your youth ATV in safe and top-running condition with this guide.
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--- Page 1 ---
ZR 120
2014
SERVICE MANUAL
[SNOWMOBILE]
--- Page 3 ---
9. At this point, scribe a line at the front of the engine 13. Remove the engine from the engine compartment.
and measure the distance between the crankshaft
and the driveshaft. Record the measurement for
installing purposes. Disassembling
1. Remove the oil drain plug and drain the oil; then
install the oil plug and tighten securely.
A048
10. Lay the snowmobile on its side.
NOTE: A piece of cardboard should be used to protect
the finish. IO063
2. Remove the cover from the air cleaner case; then
11. Using a flat-blade screwdriver, remove the four disconnect the breather hose and remove the filter
belly pan plugs covering the engine mounting cap and retaining plate.
screws; then remove the cap screws and lock nuts.
NOTE: The retaining plate is directional.
IO061A
IO056A
NOTE: The front center plug is to access the oil drain
plug. 3. Remove the two cap screws securing the air
cleaner case to the intake tube; then remove the
12. Place the snowmobile in the upright position; then cap screw and lock nut securing the case to the
on the left-hand side of the engine, remove the throttle cable bracket, remove the air cleaner case
three cap screws securing the engine and brake and account for the intake tube gasket.
bracket to the front end.
IO064A
IO062A
8
--- Page 4 ---
CARBURETOR INSULATOR PLATE
1. Inspect for cracks, scoring, pitting, imperfections,
or warping.
2. Inspect the sealing surfaces for trueness by placing
each on the surface plate covered with #400 grit
wet-or-dry sandpaper. Using light pressure, move
both sides in a figure eight motion. Inspect the
sealing surfaces for any indication of high spots or
warping. Correct highs spots by continuing to
move each side in a figure eight motion. Warped
components must be replaced.
GEN-0039
CRANKSHAFT BEARINGS
A932
CAUTION
Water or parts-cleaning solvent must be used in con-
0744-992
junction with the wet-or-dry sandpaper or damage to
Removing the sealing surfaces may result.
1. Using a flat-blade screwdriver, carefully work the
oil seal from side-to-side out of the crankcase and Assembling
cover.
2. Using a suitable press and with the crankcase or NOTE: The use of new gaskets and seals is recom-
crankcase cover secured into position, carefully mended when assembling the engine.
heat the case; then press the bearings out of the
case. NOTE: Prior to assembling the engine, use parts
cleaning solvent and compressed air and thoroughly
CAUTION clean the threaded holes of the crankcase and cylinder
Never reuse the crankshaft bearings. If the bearings and head to properly tighten.
have been pressed out of the crankcase or crankcase
cover, they must be discarded. ! WARNING
Always wear safety glasses when drying components
NOTE: Thoroughly clean the bearing areas of the
with compressed air.
crankcase and crankcase cover and inspect for any
nicks or imperfections of the bearing bosses of the NOTE: When the use of a lubrication is indicated, use
case.
clean engine oil.
Installing 1. Lubricate the piston pin, connecting rod, and pis-
1. Secure the crankcase and press the new bearing ton pin bore with engine oil; then install the piston
into the boss of the crankcase and crankcase cover. to the connecting rod and secure the piston pin
with the circlips directed either up or down.
CAUTION
When installing the new bearings, always press
against the outside race of the bearing.
2. With the bearings installed and using a suitable
seal driver, install the oil seals with the spring side
of the seal facing the bearing; then coat the wear
surfaces of the seals with a film of grease.
18
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4. Remove the float pin (D) securing the float (E) to 7. Place the carburetor insulator on a surface plate
the carburetor body; then remove the float and covered with #400 grit wet-or-dry sandpaper.
needle jet assembly (F). Move the insulator over the surface plate using a
figure eight motion. The motion should produce
5. Remove the main jet (G) and the nozzle (H) from an even wear pattern over the entire sealing area.
the carburetor tower.
CLEANING CAUTION
Water or parts-cleaning solvent must be used in con-
CAUTION junction with the wet-or-dry sandpaper or damage to
DO NOT place any non-metallic components in parts- the sealing surfaces may result.
cleaning solvent or carburetor cleaner because dam-
age or deterioration will result.
1. Place all metallic components in a wire basket and
submerge in carburetor cleaner.
2. Soak for approximately 30 minutes; then rinse
with fresh parts-cleaning solvent.
3. Wash all non-metallic components with soap and
water. Rinse thoroughly.
4. Dry all components with compressed air only
making sure all holes, orifices, and channels are
unobstructed. A739
5. Blow compressed air through all hoses to remove 8. Inspect the condition of the throttle return spring.
any obstructions. CHECKING FLOAT HEIGHT
! WARNING 1. Remove the cap screw securing the float chamber;
then remove the float chamber from the carburetor
Always wear safety glasses when drying components and account for the rubber gasket.
with compressed air.
2. With the carburetor in an upside-down position,
CAUTION lift the float so the tip of the float lightly contacts
DO NOT use wire or small drill bits to clean carburetor the float arm; then measure the float height from
orifices, holes, or channels. Distorted or damaged ori- the body of the carburetor and under-side of the
fices, holes, or channels can result in poor carburetor float. Measurement should be 0.63".
operation.
INSPECTING
1. Inspect the mixing body and jet orifices for cracks,
nicks, stripped threads, and any other imperfec-
tions in the casting.
2. Inspect the float for perforations or damage.
3. Inspect the gaskets for distortion, tears, or notice-
able damage.
4. When applicable, inspect the idle fuel adjuster
screw, needle jet assembly, and pilot jet for wear,
damage, or distortion. IO108
5. Inspect the nozzle and main jet for obstructions or CAUTION
damage.
Do not bend the float in an attempt to adjust the
6. Inspect the carburetor insulator for damage, height. Correct float height is obtained by replacing
cracks, and tightness. the needle jet assembly and/or the float.
CAUTION
An air leak between the carburetor and engine will
cause a lean condition and poor engine performance.
28
--- Page 6 ---
3. Place the upper idler wheel assembly into position
in the tunnel; then secure with cap screws. Tighten
securely.
4. Install the skid frame (see Rear Suspension sec-
tion).
5. Place the snowmobile in the upright position.
6. Place the key on the driveshaft; then slide the
chain sprocket w/chain onto the driveshaft. Secure
with a cap screw (coated with red Loctite #271)
and washer. Tighten to 20 ft-lb.
7. Inspect the chain for proper engagement with the 0744-945
clutch sprocket and the chain sprocket.
Adjusting
8. Inspect that the chain tensioner assembly is in
place and functioning properly. 1. Loosen the idler wheel cap screws.
9. Install the rear sprocket cover and secure with the 2. Loosen the rear idler wheel adjusting bolt jam nuts.
self-tapping screws. Tighten securely.
NOTE: At this point, proceed to TRACK TENSION sub-
section.
TRACK TENSION
NOTE: Track tension and track alignment are interre-
lated; therefore, always check both, even if only one
adjustment seems necessary.
Track tension is directly related to the overall perfor-
mance of the snowmobile. If the track is too loose, it may
slap against the tunnel causing wear, or it may ratchet on
the track drive sprockets. Arctic Cat recommends that the 0744-947
track tension be checked once a month and adjusted
accordingly. NOTE: To ensure proper track tension adjustment, per-
form all adjustments on both sides of the snowmobile.
! WARNING
Track tension must be properly maintained. Personal 3. If the deflection (distance between the bottom of
injury could result if a track is allowed to become the wear strip and the inside of the track) exceeds
excessively loose. specifications, tighten the adjusting bolts to take
up excessive slack in the track.
Checking
4. If the distance between the bottom of the wear
! WARNING strip and the inside surface of the track is less than
DO NOT attempt to check or adjust track tension with specified, loosen the adjusting bolts to increase the
engine running. Turn ignition key to the OFF position. slack in the track.
Personal injury could result from contact with a rotat-
5. Check track alignment (see TRACK ALIGN-
ing track.
MENT sub-section).
1. Remove excess ice and snow buildup from the
track, track drive sprockets, and the inside of the 6. When proper track tension is obtained, tighten the
skid frame. adjusting bolt jam nuts against the axle housings.
2. Place the rear of the snowmobile up on a safety 7. Tighten the idler wheel cap screws securely.
stand high enough so the track is free of the floor. NOTE: Since track tension and track alignment are
3. Without exerting any pressure on the track, mea- interrelated, always check both even if only one adjust-
sure the distance between the bottom of the wear ment seems necessary.
strip and the inside surface of the track. The mea-
surement must be within specifications. If the
measurement is not within 1/4-3/8 in., an adjust-
ment is necessary.
38
--- Page 7 ---
AO162 AO161
4. Secure the rear arm to the support bracket with the 7. Place the end cap onto the rail and secure with the
cap screw. Tighten securely. cap screw, washers, and lock nut. Tighten to 78 in.-
lb.
Installing Skid Frame
1. Place a piece of cardboard on the floor to protect
against scratching and tip the snowmobile onto
one side.
2. Pull the track away from the tunnel and spread
open; then place the skid frame into the track.
3. Position the front of the skid frame into the tunnel
AO159
and align the front axle with the appropriate
mounting holes in the tunnel. Secure the axle to
5. Secure the cross-brace axle to the slide rail with the tunnel with the cap screws (coated with blue
the cap screw (threads coated with blue Loctite Loctite #243). Thread the cap screws in only half
#243). Tighten to 20 ft-lb. way. DO NOT TIGHTEN AT THIS TIME.
NOTE: To aid in centering the rear arm with the holes
in the tunnel, position the skid frame and track at a 45°
angle to the bottom of the tunnel.
4. Align the rear idler axle with the appropriate
mounting holes in the tunnel. Secure the axle to
the tunnel with the cap screws (coated with blue
Loctite #243). Thread the cap screws in only half
way. DO NOT TIGHTEN AT THIS TIME.
5. Align the rear arm with the holes in the arm sup-
port bracket. Secure the arm to the bracket with
the cap screws (threads coated with blue Loctite
AO160 #243). Tighten to 20 ft-lb.
6. Place the shock pad into position and secure with a 6. Place the snowmobile in the upright position.
solid rivet and push nut.
7. Securely tighten all mounting hardware (from
steps 3 and 4) to 20 ft-lb.
8. Check track tension; adjust as necessary (see
Track and Driveshaft section).
48