Arctic Cat ZR 120 Service Manual

[SNOWMOBILE]SERVICE MANUAL2014ZR 120

7EngineThis engine section has been organized into sub-sectionsshowing a progression for the complete servicing of theArctic Cat 120 cc engine. For co

89. At this point, scribe a line at the front of the engineand measure the distance between the crankshaftand the driveshaft. Record the measurement f

94. Remove the two springs from the governor arm,throttle cable bracket, and retaining bracket.IO065ANOTE: For assembling purposes, note the location

10IO07112. Remove the lock nuts and rocker arm pivots secur-ing the rocker arms to the cylinder head.13. Remove the push rods; then remove the push ro

11IO094BIO07719. With the piston at TDC, scribe an alignment markon the gear of the camshaft directly in-line withthe alignment dot on the crankshaft

12NOTE: If the seals or bearings of the crankshaft needto be replaced, see Crankshaft Bearings in ServicingComponents.Servicing ComponentsThoroughly

13Measuring Valve Guide/Valve Stem Clearance1. Using a micrometer and small bore gauge, takediameter readings on the valve stems and insidethe guides.

14IO088Measuring Camshaft End Running Surfaces1. Using an outside micrometer, measure the runningsurfaces of each end of the camshaft. The mea-suremen

15IO090Piston Ring/Groove Clearance1. Using a thickness gauge, measure the side clear-ances of the 1st and 2nd rings.2. If the measurements are not wi

16ATV-1069CYLINDER/CYLINDER HEADNOTE: If the cylinder/cylinder head assembly cannotbe trued, they must be replaced.Cleaning/Inspecting Cylinder Head1

FOREWORDThis Arctic Cat Service Manual contains service and maintenance information for the 2014 Arctic Cat ZR 120 Snowmo-bile. The manual is designed

17GEN-00343. If the difference between the connecting rod smallend bore inside diameter and the piston pin outsidediameter exceeds the limit, replace

18GEN-0039CRANKSHAFT BEARINGS0744-992Removing1. Using a flat-blade screwdriver, carefully work theoil seal from side-to-side out of the crankcase andc

19IO091ANOTE: Coat the cylinder wall, connecting rod bearingsurface, and the crankshaft with engine oil.2. Install the crankshaft into the crankcase;

20IO101NOTE: When installing the governor control shaft,position the shaft so the flat end (A) of the shaft isdirected to the cylinder (3 o’clock pos

21IO10713. Set the valve clearance to the recommended set-ting with a feeler gauge, and while holding theadjustment nut, tighten the rocker arm lock n

2220. Rotate the flywheel until the magnet of the fly-wheel is under the legs of the ignition coil; theninsert a flat 0.020" feeler gauge between

23IO10427. With a gasket in place on the intake tube, installthe air cleaner case, and with gasket, insulatorplate, and cap screws, secure the case to

24IO060A12. Position the throttle cable in the bracket; then con-nect the cable to the throttle lever. Tighten theadjustment jam nuts securely.IO057B

25NOTE: The engine must be removed to access therecoil starter (see Engine section).REMOVING/DISASSEMBLING1. Remove the cap screws (A) securing the r

26Troubleshooting EngineProblem: Engine Does Not Start (No Spark at Spark Plug)Condition Remedy1. Ground connections dirty — loose2. Wiring harness sh

27Fuel SystemThis section has been organized for servicing the fuelsystem. The technician should use discretion and soundjudgment when removing/disass

284. Remove the float pin (D) securing the float (E) tothe carburetor body; then remove the float andneedle jet assembly (F).5. Remove the main jet (G

29ASSEMBLING744-959A1. Install the nozzle (H) and main jet (G) into the car-buretor tower.2. Place the needle jet assembly (F) and the float (E)into p

30IO110BThrottle CableThe correct throttle cable adjustment is when (with theengine OFF) the carburetor throttle is completely open(against its limit)

313. Remove the C-clip securing the cable in the throt-tle control; then remove the cable from the throttlecontrol.A981A9824. Remove the handlebar pad

32Troubleshooting Fuel SystemProblem: Carburetor Too Rich (0-1/4 Opening)Condition Remedy1. Choke valve will not seat2. Idle fuel adjuster screw out o

33Electrical SystemTESTING COMPONENTSFollowing are testing procedures for specific electricalcomponents. All tests of the electrical componentsshould

34D. Defective tetherTesting Ignition Switches1. Disconnect the engine wires from the main wiringharness.2. At the main wiring harness engine connecto

35Drive Chain and SprocketsREMOVING1. Remove the self-tapping screws securing the frontclutch shield and rear sprocket cover; then removefrom the engi

365. Inspect the chain and chain sprocket for wear ordamage.6. Inspect the driveshaft sprockets for wear or damage.INSTALLING1. Slide the chain sprock

1TABLE OF CONTENTSGeneral Information ... 2Snowmobile Identification...

374. Remove the cap screws securing the upper idlerwheel assembly to the tunnel; then remove theassembly from the tunnel.IO115A5. Remove the four lock

383. Place the upper idler wheel assembly into positionin the tunnel; then secure with cap screws. Tightensecurely.4. Install the skid frame (see Rear

39TRACK ALIGNMENTProper track alignment is obtained when the rear idlerwheels are equal distance from the inner track drive lugs.Excessive wear to the

40Brake SystemREMOVING AND INSPECTING742-425B1. Remove the front clutch shield and hood cable.NOTE: It will be necessary to reinstall the hood cableo

41A9983. Place the brake band into position on the bracketand secure with a washer and retaining ring.IO117A4. Slide the spring onto the brake cable;

42Troubleshooting TrackProblem: Track Edge Frayed — Drive Lugs WornCondition Remedy1. Track alignment adjusted incorrectly 1. Align — replace trackPro

43Rear SuspensionGENERAL INFORMATIONQuick acceleration and the ability to go through the turnswith power are the most important handling qualities.Thi

44End CapREMOVING1. Remove the lock nut, washers, and cap screwsecuring the end cap.AG297D2. Using a hammer, tap the end cap off the rail.CLEANING AND

453. Using a straightedge, inspect the slide rail for anyunusual bends. Place the straightedge along thebottom surface of the slide rail. If the rail

46DISASSEMBLING1. With the skid frame removed, remove the capscrews and flat washers securing the outer idlerwheels. Remove the idler wheels from the

2General InformationNOTE: Whenever a part is worn excessively, cracked,or damaged in any way, replacement is necessary.NOTE: Some illustrations and

47AG297D2. Remove the cap screw securing the cross-brace axleto the slide rail.AO1603. Remove the cap screw securing the rear suspen-sion arm to the s

48AO1624. Secure the rear arm to the support bracket with thecap screw. Tighten securely.AO1595. Secure the cross-brace axle to the slide rail withthe

49Steering and BodySteering PostREMOVINGNOTE: Perform steps 1-8 for both the brake and throt-tle cables.1. Remove the handlebar pad.2. Remove the C-c

50IO059A10. Pull the steering post up and out of the lower bear-ing.11. Remove the lock nuts and cap screws securing thetie rods to the steering post.

515. Tighten the upper and lower retainer cap screwssecurely.A026NOTE: Check all fasteners to ensure they are tight.Turn the handlebar full-left and

52SkiREMOVING1. Remove the cap screw and lock nut securing theski to the spindle.2. Remove the ski and account for two washers.INSPECTING1. Inspect al

533. Wash the ball joint in parts-cleaning solvent. Drywith compressed air. Inspect the ball joint pivotarea for wear. Apply an all-temperature grease

543. Inspect the suspension arm axle area for wear.4. Secure the spindle in a vise. Rotate the spindleclockwise and counterclockwise. The movementshou

554. While holding the straight ski in position, rotatethe tie rod until the measurement between the skisis within specifications.5. When the ski alig

563. Using the Shock Spring Removal Tool, removethe spring from the shock body by compressingthe spring; then remove the spring retainer fromthe top o

3During break-in, a maximum of 1/2 throttle is recom-mended; however, brief full-throttle accelerations andvariations in driving speeds contribute to

57Seat/Cushion/Taillight Housing0747-299REMOVING1. Remove the retaining nut securing the ignitionswitch to the console; then slide the switch for-ward

588. Connect the fuel hose to the carburetor and turnthe gas tank shut-off valve to the OPEN position.Headlight AssemblyREMOVINGNOTE: The bulb portio

59Wiring Diagram0744-204

60NOTES

Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-960

43. Check all control wires and cables for signs ofwear or fraying. Replace if necessary. Use cableties or tape to route wires and cables away fromhot

5Engine Torque DiagramNOTE: Before engine assembly, ensure all threaded areas are clean to assure an accurate torque value isachieved. Torque values

6Engine Specifications Carburetor SpecificationsTrack SpecificationsSki Shock Spring SpecificationsRear Arm Spring SpecificationsSki Shock Absorber Sp