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

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2020 Arctic Cat ZR 9000 Thundercat ATV Service Manual

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

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Table Of Contents:

2020 Arctic Cat ZR 9000 Thundercat ATV 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 Switches………………………………………80
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 Clutch……………………………………………………………….82
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

Description:

2020 Arctic Cat ZR 9000 Thundercat ATV Service Manual

• 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

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]