2020 Arctic Cat Snowmobile ZR 9000 Thundercat Service Manual – PDF DOWNLOAD

Description

2020 Arctic Cat Snowmobile ZR 9000 Thundercat Service Manual

DESCRIPTION:

2020 Arctic Cat Snowmobile ZR 9000 Thundercat Service Manual

FOREWORD:

This Service Manual contains service and maintenance information for 2020 Arctic Cat ZR 9000 Thundercat snowmobile models. The manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections that cover specific snowmobile components or systems and, in addition to the standard service procedures, include 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.

• The service technician should become familiar with the operation and construction of the components or systems by carefully studying the complete manual. This will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize important information.
• The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identifies unsafe practices which may result in snowmobile- related damage.
• Follow the directive because it deals with the possibility of damaging part or parts of the snowmobile. The symbol  NOTE: identifies supplementary information worthy of particular attention. At the time of publication, all information, photographs, and illustrations were technically correct.
• Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice.

TABLE OF CONTENTS:

2020 Arctic Cat Snowmobile ZR 9000 Thundercat Service Manual

General Information/Foreword 2
Snowmobile Identification 2
Recommended Gasoline and Oil 2
Engine Break-In 2
Drive Belt Break-In 3
Genuine Parts 3
Varying Altitude Operation 3
Preparation for Storage 4
Preparation after Storage 4
After Break-In Checkup/Checklist 5
Engine Specifications 5
Electrical Specifications 6
Drive System Specifications 6
Drive Clutch/Driven Clutch-Related Specifications 6
Drive System Components 6
Chain Case Performance Calibrations 7
Track Specifications 7
IFP Shock Specifications 7
Torque Conversions 7
Torque Specifications 8
Steering and Body 9
Steering Post 9
Ski 10
Ski Wear Bar 11
Spindle 11
Steering Tie Rod 12
Ski Alignment 13
A-Arms 14
Ski Shock Absorber 16
Sway Bar 16
Front Bumper 17
Seat Assembly 17
Seat Cushion 17
Taillight/Brake Light Assembly 17
Rear Bumper/Snowflap 17
Windshield/Console/ Headlight 18
Adjusting Headlight Aim 19
Engine 20
Engine Removing/Installing 20
Engine Servicing 28
Assembly Schematic 49
Troubleshooting Engine 51
Engine-Related Items 53
Water Pump 53
Pressure Testing Engine 55
Checking Compression 55
Changing Oil/Filter 55
Liquid Cooling System 56
Cooling System Schematic 57
Heat Exchanger 58
Air Silencer 59
Turbocharger/Intercooler 60
Fuel Systems 64
Fuel System 64
Individual Components 64
Self-Diagnostic System/Codes 66
Fuel Pressure Regulator 67
Throttle Cable 67
Fuel Pump 68
Gas Tank 69
Electrical Systems 70
Ignition System 70
Throttle Position Sensor 70
Electrical Resistance Tests 71
Voltage Regulator Tests 72
Testing Fuel Gauge Sender 72
Emergency Stop Switch 73
Starter Relay Solenoid 73
Fuse 73
Ignition Switch 73
Starter Motor 74
Troubleshooting Electric Start 76
Magneto 77
Brake Light Switch 78
Testing Headlight Dimmer Switch 79
Testing Handlebar Warmer Elements 79
Testing Thumb Warmer Element 79
Testing Handlebar Warmer/Thumb Warmer Switch 79
Testing Passenger Handwarmer Switch 79
Testing Passenger Handwarmer Elements 80
Testing Seat Heater Switches80
Testing Speedometer Sensor 80
Testing Gear Position Switch 81
Testing Shift Switch 81
Testing Shift Actuator 81
Testing Heated Shield Outlet 81
Drivetrain/Track/Brake Systems 82
Drive Belt 82
Drive Clutch82
Driven Clutch 84
Drive Clutch/Driven Clutch 86
Drivetrain 87
Drive Sprockets 91
Track Tension 93
Track Alignment 94
Brake System 95
Brake Lever/Master Cylinder Assembly 100
Troubleshooting Drive Clutch/Driven Clutch 101
Troubleshooting Track 102
Troubleshooting Hydraulic Brake System 102
Suspension 103
Suspension Setup Basics 103
Chassis and Skid Frame Mounting Locations 107
Servicing Suspension 107
Servicing IFP Shock 115

2020 ARCTIC CAT SNOWMOBILE ZR 9000 THUNDERCAT SERVICE MANUAL – PDF DOWNLOAD:

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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