Arctic Cat ZR 120 Service Manual download pdf (Page 10)

Engine

This engine section has been organized into sub-sections

showing a progression for the complete servicing of the

Arctic Cat 120 cc engine. For consistency purposes, this

section shows a complete and thorough progression;

however, for efficiency it may be preferable to remove

and disassemble only those components needing to be

addressed and to service only those components. Also,

some components may vary. The technician should use

discretion and sound judgment.

Removing



NOTE: The drive chain must be removed in order to

remove the engine (see Drive Chain and Sprockets sec-

tion).

1. Loosen the pinch screw and jam nuts (A) securing

the choke cable to the carburetor; then loosen the

throttle cable jam nuts (B) and remove the cable

from the mounting bracket. Secure the cables out

of the way.

IO057A

2. Turn the gas tank shut-off valve to the CLOSED

position; then disconnect the fuel hose from the

carburetor.

3. Remove the two cap screws securing the steering

post to the steering post support. Account for two

bearing halves, two lock nuts, and a bearing

retainer.

IO059A

4. Pull the steering post up and back and then out of

the lower steering post bearing.

5. Remove the two lock nuts and cap screws securing

the tie rods to the steering post; then remove the tie

rods from the steering post. Place the steering post

out of the way on the right-hand side of the engine

compartment.

IO060A

6. Cut the cable tie; then disconnect the coil and two

magneto wires at the front of the engine. Route

them out of the way.

A047

7. Pull the recoil starter rope out for enough to tie a

slip-knot in the starter rope below the console and

allow the rope to slowly retract against the recoil

starter.

8. Remove the knot at the handle and remove the

handle; then thread the rope through the bushing in

the console.

! WARNING

Whenever any maintenance or inspection is made on

a fuel system when there may be fuel leakage, there

should be no welding, smoking, open flames, etc., in

the area.

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Arctic Cat ZR 120 Service Manual Page 10

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