2015 Arctic Cat ZR 120 ATV Service Manual – PDF DOWNLOAD

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2015 Arctic Cat ZR 120 ATV Service Manual

2015 ARCTIC CAT ZR 120 ATV SERVICE MANUAL – PDF DOWNLOAD:

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Table Of Content:

2015 Arctic Cat ZR 120 ATV Service Manual

General Information …………………………………………… 2
Snowmobile Identification…………………………….. 2
Recommended Gasoline and Oil ………………….. 2
Break-In Procedure …………………………………….. 2
Genuine Parts ……………………………………………. 3
Drive Chain Lubrication ……………………………….. 3
Preparation For Storage………………………………. 3
Preparation After Storage…………………………….. 3
Torque Conversions (ft-lb/N-m) …………………….. 4
Torque Specifications ………………………………….. 4
Engine Torque Diagram……………………………….. 5
Engine Specifications………………………………….. 6
Carburetor Specifications …………………………….. 6
Track Specifications…………………………………….. 6
Ski Shock Spring Specifications……………………. 6
Rear Arm Spring Specifications ……………………. 6
Ski Shock Absorber Specifications………………… 6
Idler Wheel Dimensions ………………………………. 6
Engine……………………………………………………………… 7
Removing ………………………………………………….. 7
Disassembling……………………………………………. 8
Servicing Components ………………………………. 12
Assembling………………………………………………. 18
Installing ………………………………………………….. 23
Changing Oil ……………………………………………. 24
Recoil Starter …………………………………………… 24
Troubleshooting Engine……………………………… 26
Fuel System……………………………………………………. 27
Pre-Maintenance Checks …………………………… 27
Carburetor ……………………………………………….. 27
Throttle Cable…………………………………………… 30
Troubleshooting Fuel System……………………… 32
Electrical System……………………………………………… 33
Transistorized Ignition System…………………….. 33
Testing Ignition Switches ……………………………. 34
Testing Electrical Resistances…………………….. 34
Drive Chain and Sprockets………………………………… 35
Track and Driveshaft…………………………………………. 36
Brake System………………………………………………….. 40
Troubleshooting Track ………………………………………. 42
Rear Suspension……………………………………………… 43
Removing Skid Frame ……………………………….. 43
End Cap ………………………………………………….. 44
Wear Strip………………………………………………… 44
Rear Suspension Arm/Rear Springs ……………. 45
Rear Idler Wheels and Axle………………………… 45
Upper Idler Wheels……………………………………. 46
Slide Rail …………………………………………………. 46
Installing Skid Frame …………………………………. 48
Steering and Body……………………………………………. 49
Steering Post ……………………………………………. 49
Ski …………………………………………………………. 52
Ski Wear Bar ……………………………………………. 52
Tie Rods …………………………………………………. 52
Spindle …………………………………………………… 53
Ski Alignment …………………………………………… 54
Front Suspension A-Arms …………………………. 55
Front Suspension (Ski) Shock Absorber……….. 55
Belly Pan …………………………………………………. 56
Seat/Cushion/Taillight Housing …………………… 57
Headlight Assembly ………………………………….. 58
Wiring Diagram ……………………………………………….. 59

Description:

2015 Arctic Cat ZR 120 ATV Service Manual

• This Arctic Cat Service Manual contains service and maintenance information for the 2015 Arctic Cat ZR 120 Snowmobile. The manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections.
• The sections cover specific snowmobile components or systems and, in addition to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
• This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.
• The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools. All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize important information.
• The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the snowmobile.
• The symbol  NOTE: identifies supplementary information worthy of particular attention. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
• Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]