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ZR/XF/M 4000/6000/8000
TABLE OF CONTENTS
General Information/Foreword ............................................... 2
Snowmobile Identification ........................................................ 2
Recommended Gasoline and Oil ............................................. 2
Engine Break-In ....................................................................... 3
Drive Belt Break-In ................................................................... 3
Genuine Parts .......................................................................... 3
Varying Altitude Operation ....................................................... 3
Preparation For Storage........................................................... 5
Preparation After Storage ........................................................ 5
After Break-In Checkup/Checklist ............................................ 6
Engine Specifications............................................................... 7
Crankshaft Runout/Repair Specifications ................................ 7
Electrical Specifications ........................................................... 9
Arctic Power Valve (APV) System Specifications..................... 8
Drive Clutch/Driven Clutch-Related Specifications ................ 10
Drive System Specifications................................................... 10
Drive System Components .................................................... 10
Chain Case Performance Calibrations ................................... 10
Track Specifications ............................................................... 13
Suspension Specifications ..................................................... 13
Torque Conversions ............................................................... 13
Torque Specifications............................................................. 14
Steering and Body ................................................................. 15
Steering Post (ZR/XF)............................................................ 15
Steering Post (XF HC) ........................................................... 16
Steering Post (M) ................................................................... 19
Ski (ZR/XF) ............................................................................ 22
Ski (XF HC/M) ........................................................................ 23
Ski Wear Bar .......................................................................... 23
Spindle (ZR/XF) ..................................................................... 24
Spindle (XF HC/M) ................................................................. 24
Steering Tie Rod .................................................................... 25
Ski Alignment ......................................................................... 26
A-Arms (ZR/XF) ..................................................................... 28
A-Arms (XF HC/M)................................................................. 29
Ski Shock Absorber................................................................ 30
Sway Bar (ZR/XF) .................................................................. 31
Front Bumper ......................................................................... 31
Seat Assembly (ZR/XF/M STD) ............................................. 31
Seat Assembly (M Sno Pro/HCR/LTD)................................... 32
Taillight/Brakelight Assembly.................................................. 32
Rear Bumper/Snowflap .......................................................... 33
Windshield/Console/ Headlight .............................................. 33
Headlight Bulb........................................................................ 34
Adjusting Headlight Aim ........................................................ 34
Engine..................................................................................... 36
Engine Removing/Installing - 4000 ........................................36
Assembly Schematic - 4000................................................... 40
Engine Removing/Installing - 6000 ........................................42
Assembly Schematic - 6000................................................... 48
Engine Removing/Installing - 8000 ........................................50
Assembly Schematic - 8000................................................... 56
Engine Servicing - 4000......................................................... 58
Engine Servicing - 6000......................................................... 73
Engine Servicing - 8000......................................................... 87
Troubleshooting Engine........................................................ 104
Engine-Related Items........................................................... 106
Water Pump - 4000 .............................................................. 106
Water Pump - 6000 .............................................................. 109
Water Pump - 8000 .............................................................. 112
Pressure Testing Engine ...................................................... 115
Liquid Cooling System ......................................................... 115
Cooling System Schematic .................................................. 116
Recoil Starter ....................................................................... 117
Arctic Power Valve (APV) System ....................................... 118
Exhaust Controlled Timing (ECT) System ........................... 122
Fuel Systems ........................................................................123
EFI System .......................................................................... 123
Individual Components ........................................................ 123
Self-Diagnostic System/Codes (4000)................................. 126
Self-Diagnostic System/Codes (6000)................................. 127
Self-Diagnostic System/Codes (8000)................................. 127
Fuel Pressure Regulator...................................................... 128
Throttle Body Assembly....................................................... 128
Throttle Cable ...................................................................... 129
Fuel Filter (6000) ................................................................. 130
Fuel Pump ........................................................................... 130
Troubleshooting ................................................................... 132
Oil-Injection Pump (4000/8000)........................................... 133
Electric Oil Pump (6000)...................................................... 134
Gas Tank ............................................................................. 135
Electrical Systems ...............................................................137
Ignition System .................................................................... 137
Throttle Position Sensor ...................................................... 138
Electrical Resistance Tests.................................................. 139
Testing Electric Oil Pump (6000) ......................................... 141
Testing Voltage Regulator.................................................... 141
Chassis Control Unit (CCU)/Codes (4000) .......................... 142
Testing Oil Level Sensor ...................................................... 142
Testing Fuel Gauge Sender................................................. 143
Emergency Stop Switch ...................................................... 143
Starter Relay Solenoid......................................................... 143
Fuse..................................................................................... 144
Ignition Switch ..................................................................... 144
Starter Motor........................................................................ 144
Troubleshooting Electric Start.............................................. 149
Ignition Timing ..................................................................... 149
Brakelight Switch ................................................................. 150
Headlight Dimmer Switch .................................................... 150
Testing Handlebar Warmer Elements ................................. 151
Testing Thumb Warmer Element ......................................... 151
Testing Handlebar Warmer/Thumb Warmer Switch ............ 151
Testing Speedometer Sensor .............................................. 152
Testing Shift Switch ............................................................. 152
Testing Servomotor/Potentiometer ...................................... 152
Troubleshooting Servomotor................................................ 154
Voltage/Resistance Chart - Air Temperature (8000) ............ 156
Voltage/Resistance Chart - Air Temperature (6000) ............ 156
Voltage/Resistance Chart - Coolant Temperature ............... 157
Drive Train/Track/Brake Systems .......................................158
Drive Belt ............................................................................. 158
Drive Clutch ......................................................................... 159
Driven Clutch ....................................................................... 162
Drive Clutch/Driven Clutch................................................... 168
Drive Train............................................................................ 170
Drive Sprockets ................................................................... 175
Track Tension....................................................................... 177
Track Alignment ................................................................... 178
Brake System ...................................................................... 179
Brake Lever/Master Cylinder Assembly............................... 183
Troubleshooting Hydraulic Brake System ............................ 185
Troubleshooting Track .......................................................... 185
Troubleshooting Drive Clutch/Driven Clutch ........................ 186
Suspension...........................................................................187
Suspension Setup Basics.................................................... 187
Servicing Suspension .......................................................... 193
FOX Air Shocks ................................................................... 204
Servicing IFP Shock ............................................................ 204
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