O P E R A T O R ’ S M A N U A L

www.arcticcat.com

PANTERA® 7000ZR® 4000

Limited Warranty Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on eachnew Arctic Cat Snowmobile it assembles and on each genuine Arctic Cat Snowmobile part and accessoryassembled and sold by an authorized Arctic Cat Snowmobile dealer. The limited warranty on an Arctic CatSnowmobile is extended to the original retail purchaser for the time periods described below; however, thebalance of the remaining warranty may be transferred to another party unless the purchase is forcommercial use (see below). Warranty coverage is only available in the country in which the original retailpurchase occurs to the original retail purchaser resident in that country or to a transferee resident in thatcountry of the balance of the remaining warranty.

Arctic Cat warrants only the products it assembles and/or sells and does not warrant that other products willfunction properly when used with an Arctic Cat Snowmobile or will not damage the Arctic Cat Snowmobile.Arctic Cat does not assume any liability for incidental or consequential damages.

Arctic Cat will repair or replace, at its option, free of charge (including any related labor charges), any partsthat are found to be warrantable in material or workmanship. This repair work MUST be done by anauthorized Arctic Cat Snowmobile dealer. No transportation charges, rental charges, or inconvenience costswill be paid by Arctic Cat. The warranty is validated upon examination of said parts by Arctic Cat or anauthorized Arctic Cat Snowmobile dealer. Arctic Cat reserves the right to inspect such parts at its factory forfinal determination if warranty should apply.The warranty periods are as follows:

1. For snowmobiles used for recreational purposes:—If purchased between May 1 and November 30, warranty expires ONE (1) YEAR from December 1of the current year.—If purchased between December 1 and April 30, ONE (1) YEAR from the date of sale.

2. For snowmobiles used for commercial purposes (including rental operations), ONE (1) YEAR from thedate of invoice and/or 5000 MILES whichever comes first (non-transferable).

3. THIRTY (30) DAYS from date of sale of snowmobile on Arctic Cat supplied batteries.Exclusions to this warranty include normal wear, abuse (i.e. a track run on marginal snow conditionswithout proper lubrication or additional idler wheels), and the following parts:

Fuel Filter Light Bulbs Windshield Drive Belt Torn or Punctured UpholsteryWear Bars Brake Pads Spark Plugs Drive Clutch/Driven Clutch Wear PartsWear Strips Shock Absorber(s) - Standard* Shock Absorber(s) - Rebuildable*** Limited to one (1) year or 1000 miles of “normal” riding conditions - replace for defective or leaking shock,

corroded or pitted shaft, peeling chrome.** Limited to one (1) year or 1000 miles of “normal” riding conditions - rebuild for leaking shock (warranted)

- replace for defective shock, corroded or pitted shaft, peeling chrome.The following will VOID Arctic Cat’s warranty:

1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (ifstored for extended periods), and/or service as recommended in the Operator’s Manual.

2. Repairs and/or adjustments by anyone other than an authorized Arctic Cat Snowmobile dealer.3. Use of an improper fuel mixture ratio.4. Use of improper carburetor jets.5. Use of improper gasoline, lubricating oils, or spark plugs.6. An accident or subjecting the snowmobile to misuse, abuse, or negligent operation.7. Any modification, addition, or removal of parts unless instructed to do so by Arctic Cat.8. Use of the snowmobile in any way for racing purposes.9. Removal of the engine for use in another vehicle.

10. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.11. Use of parts not sold or approved by Arctic Cat.12. Track and tunnel damage resulting from either ice stud or hooker plate installation.13. Damage due to improper transportation.

Arctic Cat shall not be responsible for and this limited warranty excludes recovery of economic, punitive,consequential and incidental damages, lost profits, and loss of use. Some states or provinces do not allowthe exclusion or limitation of incidental or consequential damages, so the above limitation may not apply toyou. Arctic Cat’s aggregate liability may not exceed the price of the product. The law of the State ofMinnesota shall apply to all claims or disputes, exclusive of its conflicts of law provisions.

IMPLIED WARRANTY EXCLUSION AND DISCLAIMERTo the fullest extent permitted by law, Arctic Cat excludes and disclaims all implied warranties ofmerchantability and fitness for a particular purpose.

If you are not satisfied with warranty service or repairs, you should contact Arctic Cat at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.

Table of ContentsLimited Warranty .....................Inside Front CoverForeword ............................................................1Declaration of Conformity...................................2Snowmobile Safety Rules ..................................3General Information ......................................4-19Snowmobile Identification.................................. 4Control Locations .............................................. 4Gasoline-Oil....................................................... 5Engine Break-In................................................. 6Drive Belt Break-In ............................................ 7Cold Drive-Away Function (Pantera 7000) ........ 7Speedometer/Tachometer/Digital Gauge .......... 7Diagnostic Codes ............................................ 11Exhaust System .............................................. 12Air-Intake Silencer ........................................... 12Cooling System ............................................... 12Battery (Pantera 7000) .................................... 13Jump-Starting (Pantera 7000) ......................... 13Drive Clutch and Driven Clutch ....................... 14Drive Clutch/Driven Clutch Alignment ............. 14Fuel Pump ....................................................... 14Shock Absorbers ............................................. 15Standard-Lug Track ......................................... 15Track Studs...................................................... 15Reverse Operation (Pantera 7000/ZR 4000 LXR) ........................ 16

Adjustable Backrest (Pantera 7000) ................ 17Removable Seat .............................................. 17Detachable Hard Storage Cases (Pantera 7000 LTD)........................................ 18

Towing ............................................................. 19Operating Instructions .................................20-24Starting and Stopping Engine ......................... 20Braking ............................................................ 21Emergency Stopping ....................................... 22Throttle/Ignition Monitor Switch ....................... 23Varying Altitude Operation............................... 23

Lubrication.................................................. 25-26Chain Case......................................................25Rear Suspension .............................................26Rear Suspension .............................................26

Maintenance............................................... 27-49Periodic Maintenance Checklist.......................27Fuel System.....................................................28Fuel System.....................................................28Checking/Adding Engine Oil (ZR 4000)...........29Checking Engine Oil Level (Pantera 7000)......29Changing Engine Oil/Filter (Pantera 7000)......29Coolant Level...................................................30Spark Plugs .....................................................31Valve Clearance (Pantera 7000)......................32Battery (Pantera 7000) ....................................33Fuses (Pantera 7000) ......................................35Brake System ..................................................35Valve Clearance (Pantera 7000)......................38Chain Tension (Pantera 7000) .........................38Drive Belt .........................................................39Track Tension...................................................42Track Alignment ...............................................43Suspension......................................................44Lights ...............................................................46Ski Wear Bars..................................................47Rail Wear Strips...............................................48

Performance Tips ....................................... 50-51Preparation for Storage .............................. 52-53Preparation after Storage .................................54U.S. EPA Emission Control Statement/Warranty

Coverage (U.S. Only) ....................................55Change of Address, Ownership, or Warranty

Transfer .........................................................57Warranty Procedure/Owner

Responsibility .......................Inside Back Cover

Reference InformationWrite the appropriate information for your Arctic Cat Snowmobile in the spacesbelow.

Always use these numbers when referring to your snowmobile.

Model: _________________________________________________Date of Purchase: ________________________________________Vehicle Identification Number: _______________________________Engine Serial Number: _____________________________________Your Arctic Cat Dealer: ___________________________________Address: _______________________________________________Phone: _________________________________________________

! WARNINGA snowmobile is a very high performance vehicle. Because it does acceleraterapidly and is capable of very high speeds, it should not be operated by a nov-ice or an inexperienced operator. Never accelerate rapidly or drive at high speedbeyond the limits of visibility or without being totally familiar with the terrainand what lies in front of you. Obey speed limits and never operate at speeds thatdo not allow adequate maneuvering and stopping distances. Read and studythe entire Operator’s Manual and Safety Handbook. Failure to follow this warn-ing could result in personal injury to yourself or others.

Personal Injury• To avoid injury to yourself and others, NEVER operate the snowmobile without

first reading and understanding this manual and the Snowmobile Safety Hand-book; then follow the instructions and heed the warnings given.

• USE COMMON SENSE.• DON’T DRINK and DRIVE.• STAY IN CONTROL at ALL TIMES.• TELL YOUR FRIENDS. If you see a friend operating a snowmobile recklessly, at

excessive speeds, while intoxicated, or in other unsafe ways, don’t wait until it istoo late to warn of the consequences of snowmobile misuse. Such conductendangers everyone. TAKE AN ACTIVE ROLE IN THE SAFETY OF YOUR-SELF AND OTHERS.

Parts and AccessoriesWhen in need of replacement parts, oil, or accessories for your Arctic Cat Snowmo-bile, be sure to only use GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSO-RIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet thestandards and requirements of your Arctic Cat Snowmobile. For a complete list ofaccessories, refer to the current Arctic Cat Accessory Catalog. To aid in service andmaintenance procedures on these snowmobiles, an Illustrated Parts Manual and aService Manual are available through your local Arctic Cat Snowmobile dealer.

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ForewordCongratulations! You have chosen a quality Arctic Cat Snowmobile designed andassembled to give dependable service. Be sure, as the owner/operator of an ArcticCat Snowmobile, to become thoroughly familiar with its basic operation, mainte-nance, and off-season storage procedures. Read this manual and the accompanyingSnowmobile Safety Handbook before operating the snowmobile to learn safe andproper use of your new Arctic Cat Snowmobile. Always operate the snowmobilewithin your level of skill and current terrain conditions.

The Operator’s Manual, Snowmobile Safety Handbook, and Snowmobile Decalsdisplay the words Warning, Caution, and Note to emphasize important information.The symbol ! WARNING identifies personal safety-related information. Besure to follow the directive because it deals with the possibility of serious personalinjury or even death. A CAUTION identifies unsafe practices which may resultin snowmobile-related damage. Follow the directive because it deals with the possi-bility of damaging part or parts of the snowmobile. The symbol NOTE: identi-fies supplementary information worthy of particular attention.

This manual covers operator-related maintenance, operating instructions, and off-season storage instructions. If major repair or service is ever required, contact anauthorized Arctic Cat Snowmobile dealer for professional service.

At the time of publication, all information and illustrations were technically cor-rect. Some illustrations used in this manual are used for clarity purposes only andare not designed to depict actual conditions. Because Arctic Cat Inc. constantlyrefines and improves its products, no retroactive obligation is incurred.

This Operator’s Manual should be considered a permanent part of the snowmobileand must remain with the snowmobile at the time of resale. If the snowmobilechanges ownership more than once, contact Arctic Cat Inc., Service Department,P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.This manual was prepared by the Product Service and Warranty Department ofArctic Cat Inc.

Every Arctic Cat Snowmobile meets or exceeds the standards of the SnowmobileSafety and Certification Committee and displays the SSCC decal. Arctic Cat Inc.endorses and encourages the safe use of all snowmobiles. Always wear a helmetand eye protection. Drive with caution, observe all state and local regulations, andrespect the rights of others. ISMA members like Arctic Cat do their part to improvetrails, sponsor events, and generally support the sport of snowmobiling. As a mem-ber of the National Snowmobile Foundation, Arctic Cat Inc. promotes snowmobil-ing through education, charity, and research programs.

© 2014 Arctic Cat Inc.

Printed in U.S.A.

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Declaration of Conformity

I, the undersigned, hereby declare that the equipment specified above conforms to thedirective(s) and standard(s) as specified.

Brad DarlingVice President/General Manager - Snowmobile Division

Application of council directives:Issued by European Commission.

EMC Directive 2004/108/ECEC Machinery Directive 2006/42/EC

Type of Equipment: SnowmobileModel Numbers:

Brand Name: Arctic Cat

S2015PTUTOUSB S2015PTULXUSB S2015ZRCEFUSG S2015ZRCRRUSGS2015PTUTOOSB S2015PTULXOSB

Standards to which conformity is declared:EMC: EN 55012, EN 61000-6-2 MACHINERY: EN 12100:2010Manufacturer (if not issuing agent): Arctic Cat Inc.

601 Brooks Ave. S.Thief River Falls, MN 56701 USA

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Snowmobile Safety Rules

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General InformationSnowmobile IdentificationThe Arctic Cat Snowmobile has twoimportant identification numbers. TheVehicle Identification Number (VIN) isstamped into the tunnel near the right-side footrest. The Engine Serial Number(ESN) is stamped into the crankcase ofthe engine.

0726-383

These numbers are required by the dealerto complete warranty claims properly. Nowarranty will be allowed by Arctic CatInc. if the engine serial number or VIN isremoved or mutilated in any way.

Always provide the snowmobile name,VIN, and ESN when contacting an autho-rized Arctic Cat Snowmobile dealer forparts, service, accessories, or warranty. Ifthe complete engine must be replaced,ask the dealer to notify Arctic Cat forcorrect registration information.

Control LocationsShown are the typical control locationsfor Arctic Cat snowmobiles. Location ofa specific control will vary according tomodel.

Pantera 7000

0748-359

ZR 4000 LXR

0747-616B

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ZR 4000 RR

0746-789A

Gasoline-OilRecommended Gasoline

The recommended gasoline to use in thesesnowmobiles is 87 octane regularunleaded. In many areas, oxygenates areadded to the gasoline. Oxygenated gaso-lines containing up to 10% ethanol areacceptable gasolines.

When using ethanol blended gasoline, it isnot necessary to add a gasoline antifreezesince ethanol will prevent the accumula-tion of moisture in the fuel system.

Recommended Injection Oil (ZR 4000)

The recommended oil to use in the oil-injection system is Arctic Cat C-TEC2(p/n 6639-520 - 48 oz) or (p/n 6639-521 -2.5 gal.). This oil is specially formulatedto be used either as an injection oil or as apre-mix oil (for break-in) and meets all ofthe lubrication requirements of the ArcticCat snowmobile engine.

Recommended Engine Oil (Pantera 7000)

The recommended oil to use is C-TEC4Synthetic Oil (p/n 6639-524 - qt) or (p/n6639-525 - gal.).

After the engine break-in period, theengine oil should be changed every 2500miles and before prolonged storage.

Filling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled toits rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area.

Also, if the snowmobile is to remain on atrailer after filling the gas tank, the bed ofthe trailer must be maintained level toprevent gasoline from draining outthrough the gas tank vent hose.

The Pantera 7000 LTD features a 4.3 gal-lon auxiliary gas tank. A separate gastank cap is located beneath the cowlingjust behind the passenger seat. The auxil-iary tank is plumbed directly into themain gas tank.

XM276

CAUTIONDo not use white gas or gasolinescontaining methanol. Only Arctic Catapproved gasoline additives shouldbe used.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage.

! WARNINGAlways fill the gas tank in a well-venti-lated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running. DONOT SMOKE while filling the gas tank.

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Break-In Gas/Oil Mixing Instructions (ZR 4000)

Before mixing gasoline and oil, make surethe oil is at room temperature (20° C/68°F). Use a U.L. approved 22.7 l (6 U.S. gal.)gasoline container for mixing the gasolineand oil. To properly mix the fuel at a 100:1ratio, use the following procedure:

1. Pour gasoline into the gasoline con-tainer until approximately half full.

2. Pour 236 ml (8 fl oz) of the recom-mended 2-cycle oil into the gasolinecontainer.

3. Install cap on gasoline container andshake the mixture vigorously.

4. Fill the gasoline container with gaso-line; then cap the gasoline containerand shake the mixture vigorously.

5. Using a fine-mesh screened funnel,pour the fuel mixture from the gasolinecontainer into the snowmobile gas tank.

Engine Break-InThe Arctic Cat engine (when new orrebuilt) requires a short break-in periodbefore the engine is subjected to heavyload conditions.

ZR 4000

Arctic Cat requires that the first tankfulof fuel be premixed at a 100:1 ratio in alloil-injection models.

During the break-in period, a maximumof 1/2 throttle is recommended; however,brief full-throttle accelerations and varia-tions in driving speeds contribute to goodengine break-in. After one (1) tankfulbreak-in period, the snowmobile may betaken to an authorized Arctic Cat Snow-mobile dealer for a checkup. Thischeckup is at the discretion and theexpense of the snowmobile owner.

Pantera 7000

Premixing fuel and oil during the breakin period is not required. There is never amore important period in the life of theengine than the first 300 miles.

Since the engine is brand new, do not putan excessive load on it for the first 300miles. The various parts in the enginewear and polish themselves to the correctoperating clearances. During this period,prolonged full throttle operation or anycondition that might result in engineoverheating must be avoided.

Operating your snowmobile for the firsttime: Start the engine and let it idle for 15minutes.

0-160 km (0–100 miles): Avoid pro-longed operation above 6000 RPM.

160-500 km (100–300 miles): Avoid pro-longed operation above 8000 RPM.

500 km (300 miles) and beyond: The snow-mobile can now be operated normally.

NOTE: After 500 miles of opera-tion, the engine oil must be changedand the oil filter replaced. If anyengine trouble should occur duringthe engine break-in period, immedi-ately have a Arctic Cat dealer checkthe snowmobile.

CAUTIONNever mix oil and gasoline in thesnowmobile gas tank.

! WARNINGAlways fill the gas tank in a well-ven-tilated area. Never add gasoline to thesnowmobile gas tank near any openflames or with the engine running. DONOT SMOKE while mixing fuel or fill-ing the gas tank.

CAUTIONDO NOT exceed the one (1) tankful limi-tation of a 100:1 gas/oil break-in mix-ture. Continuous use of a gas/oilmixture, unless consistently operatingin extremely cold conditions (-26°C/-15°F or colder), could cause spark plugfouling and excessive carbon buildup. A100:1 gas/oil mixture must be used inconjunction with the oil-injection sys-tem to ensure adequate engine lubrica-tion in extremely cold conditions.

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Drive Belt Break-InDrive belts require a break-in period ofapproximately 25 miles. Drive the snow-mobile for 25 miles at 3/4 throttle or less.By revving the engine up and down (butnot exceeding 60 mph), the exposed cordon the side of a new belt will be worndown. This will allow the drive belt togain its optimum flexibility and willextend drive belt life.

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt (see DriveBelt sub-section in the Maintenancesection).

Cold Drive-Away Function (Pantera 7000)On these models, there is a “cold drive-away” function incorporated within theECM.

When cold-starting the engine, the cool-ant temperature warning icon will illumi-nate and the LOW TEMP display on thereadout screen will begin to flash. Withthe engine in this temperature range, theRPM “limit” of the engine will be belowdrive system engagement speed. As theengine warms, the coolant temperaturewarning icon will begin to flash, theLOW TEMP display will continue toflash, and the RPM “limit” of the enginewill increase allowing the snowmobile tomove without full-throttle operation.When the engine reaches proper operat-ing temperature, the coolant temperaturewarning icon and the LOW TEMP dis-play will go out.

Speedometer/Tachometer/Digital GaugeThese snowmobiles are equipped withdifferent speedometer/tachometer styles.Determine which style your model isequipped with and use the appropriatefollowing information.

ZR 4000

FZ003F

A. Low Oil Warning Icon

The Low Oil Warning Icon is designed toalert the snowmobile operator when theoil in the oil injection reservoir getsbelow a prescribed level; however, it ishighly recommended that a visual verifi-cation of the oil level in the reservoir bedone prior to operating the snowmobile.Once the Low Oil Warning Icon illumi-nates during operation of the snowmo-bile, the operator must periodicallymonitor the level of oil in the reservoirand must fill the reservoir the next timegasoline is added to the gas tank. The“alert level” of the Low Oil Warning Iconis approximately equal to 1 tankful ofgasoline under normal operating condi-tions.

B. Coolant Temperature Indicator

If the coolant temperature rises too farabove proper operating temperature, theindicator will flash a warning (alert) andthe engine will “surge” to alert the opera-tor. If the coolant temperature rises to acritical point above proper operating tem-perature, the indicator will cease flashingand will remain constantly illuminated.

C. Fuel Level Display

This bar display shows the approximate amount of gas remaining in the gas tank.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving ofthe engine could result in seriousengine damage and drive clutch fail-ure.

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D. Service Icon

If the illuminates while the engine is run-ning, the system is receiving input that isoutside of its established parameters. Ifthe icon illuminates indicating an error,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

E. High Beam Indicator

The indicator is on whenever the highbeam mode is selected by the headlightswitch.

RPM/MPH (kph)

By pushing the increment button once,the RPM and MPH will be displayed(one on the readout screen and one withthe needle). By pushing the button onceagain, the functions will be reversed.

By pushing the increment button (withspeed being displayed) for more than twoseconds, the display will change betweenstandard mph or metric kph.

With RPM displayed on the readoutscreen by pushing and holding the incre-ment button, maximum RPM will be dis-played on the readout screen. Themaximum RPM readout will reset whenthe decrement button is pushed (whilemaximum RPM is displayed).

Odometer/Trip-Meter (1)/Trip-Meter (2)/Hour-Meter

By pushing the decrement button, thereadout screen will display odometer,trip-meter (1), trip-meter (2), and hour-meter. To reset the trip meter with the tripmeter displayed, push and hold the decre-ment button until the display is cleared.The hour-meter readout will not reset.

Pantera 7000 LTD

CWI-051A

A. Coolant Temperature Indicator

When the snowmobile is started, this indica-tor will flash and LOW TEMP will be dis-played until the engine reaches operatingtemperature.

If the coolant temperature rises too farabove proper operating temperature, theindicator will flash a warning (alert) andthe engine will “surge” to alert the opera-tor. If the coolant temperature rises to acritical point above proper operating tem-perature, the indicator will cease flashingand will remain constantly illuminated.

NOTE: If the indicator is constantlyon, the engine will shut off if vehiclespeed is reduced to 1.5 km-h (0.9MPH) or slower.

B. High Beam Indicator

The indicator is on whenever the highbeam mode is selected by the headlightswitch.

C. Oil Pressure Indicator

The indicator relates to engine oil pres-sure, not the oil level; however, if the oillevel is low, it may affect oil pressure. Ifoil pressure is lost, check the oil level(see page 29).

CAUTIONIf the indicator is illuminated, stop theengine immediately and allow it to cooldown. If unable to either determine orremedy the problem, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

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If the indicator does not go out or if theengine does not start, take the snowmo-bile to an authorized Arctic Cat Snowmo-bile dealer. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

D. Low Fuel Indicator

The indicator illuminates whenever thegas in the gas tank is low.

E. Coolant Temperature/Battery Voltage/Intake Air Temperature Display

This bar display shows coolant tempera-ture, battery voltage, and intake air tem-perature. Press the Lower Left Button tochange which parameter is being dis-played. Press and hold the Lower LeftButton to see the actual values associatedwith the mode selected.

F. Fuel Level Display

This bar display shows the approximateamount of gas remaining in the gas tank.

G. RPM/Speed/Clock/Altimeter

Press the Upper Left Button to cycle theleft screen between RPM and speed.

NOTE: When RPM is displayed onthe left screen, the right screen willdisplay speed, clock, or altimeter.When speed is displayed on the leftscreen, the right screen will displayRPM, clock or altimeter.

Press the Upper Right Button to cycle theright screen between speed, RPM, clock,and altimeter.

Press and hold the Upper Button on thespeed-side of the gauge to shift betweenstandard (MPH/miles/Fahrenheit) andmetric (km/h/kilometers/Celsius).

Press and hold the Upper Button on theRPM-side to view maximum RPM. Thisvalue is reset each time the ignition key isturned off.

With the clock mode selected by pressingthe Upper Right Button, press and hold theUpper Right Button to set the clock. Theoption of selecting the 12-hour or 24-hourclock is available; press the either Left But-ton to alternate between the two modes.Next, press the Lower Right Button to setthe clock. Press either Left Button to set thehours; then press the Lower Right Button toset the minutes. Press either Left Button toset the minutes. When the proper time hasbeen set, press the Lower Right Button toreturn to the main gauge display.

With the altimeter mode selected bypressing the Upper Right Button, pressand hold the Upper Right Button to setthe current altitude by using either LeftButton. When the proper altitude hasbeen set, press the Lower Right Button toreturn to the main gauge display.

H. Engine Hour Meter/Odometer/Trip Meter/Clock

This display shows engine hours, odome-ter, trip meter, or clock. Press the LowerRight Button to change which parameteris being displayed. The Engine HourMeter and Odometer cannot be reset. Toreset the trip meter, select the Trip Meter;then press and hold the Lower Right But-ton until the trip meter display reads 0.

NOTE: The clock can only be dis-played in this position if it is notalready being displayed in the mainright screen. To set the clock whenthe clock is in this position, pressand hold the Lower Right Button;then use the procedure found in G.

Pantera 7000

XM248A

10

1. Left Button - Shifts top displaythrough speedometer, RPM, andclock.

2. Middle Button - Shifts middle dis-play through speedometer, RPM,clock, odometer, trip 1, trip 2, andengine hours.

3. Right Button - Shifts bottom displaythrough coolant temperature, bat-tery voltage, and fuel level.

4. Speedometer/Tachometer Display -Indicates approximate vehicle speedin MPH or KM/H when speedome-ter function is selected, RPM whentachometer function is selected.Press the Left Button to changewhich parameter is being displayed.With speedometer selected, pressand hold the Left Button to shiftbetween standard (MPH/miles/Fahr-enheit) and metric (km/h/kilometers/Celsius).

5. Engine Hour Meter/Odometer/TripMeter/Speedometer/Tachometer/Clock Display - Displays enginehours, odometer, trip meter, speed-ometer, tachometer, or clock. Pressthe Middle Button to change whichparameter is being displayed. TheEngine Hour Meter and Odometercannot be reset. To reset the tripmeter, select the Trip Meter; thenpress and hold the Middle Buttonuntil the trip meter display reads 0.

With the clock mode selected, pressand hold the Left Button to set theclock. The option of selecting the12-hour or 24-hour clock is avail-able; press the Left Button to alter-nate between the two modes. Next,press the Middle Button to set theclock. Press the Left or Right to setthe hours; then press the MiddleButton to set the minutes. Press theLeft or Right Button to set the min-utes. When the proper time has beenset, press the Middle Button toreturn to the main gauge display.

6. Coolant Temperature/Battery Volt-age/Fuel Level Display - Displayscoolant temperature, battery voltage,and fuel quantity. Press the RightButton to change which parameter isbeing displayed. Press and hold theRight Button to see the actual valuesassociated with the mode selected.

7. Gear Position Indicator - Indicates ifreverse is selected.

8. Coolant Temperature Indicator -When the snowmobile is started, thisindicator will flash and LOW TEMPwill be displayed until the enginereaches operating temperature.

If the coolant temperature rises toofar above proper operating tempera-ture, the indicator will flash a warn-ing (alert) and the engine will“surge” to alert the operator. If thecoolant temperature rises to a criticalpoint above proper operating tem-perature, the indicator will ceaseflashing and will remain constantlyilluminated.

NOTE: If the indicator is constantlyon, the engine will shut off if vehiclespeed is reduced to 1.5 km-h (0.9MPH) or slower.

9. High Beam Indicator - The indicatoris on whenever the high beam modeis selected by the headlight switch.

CAUTIONIf the indicator is illuminated, stop theengine immediately and allow it to cooldown. If unable to either determine orremedy the problem, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

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10. Oil Pressure Indicator - The indica-tor relates to engine oil pressure, notthe oil level; however, if the oil levelis low, it may affect oil pressure. Ifoil pressure is lost, check the oillevel. If the indicator does not go outor if the engine does not start, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer. If notunder warranty, this service is at thediscretion and expense of the snow-mobile owner.

11. Fuel Level Indicator - The indicatorwill display whenever gas is low inthe fuel tank.

Diagnostic CodesDiagnostic codes are activated by theECM and may be displayed on the read-out screen for a number of reasons. If acode is displayed while the engine is run-ning, the ECM is receiving input that isoutside of its established parameters.

If a code has been activated, take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for service. If not underwarranty, this service is at the discretionand expense of the snowmobile owner.

ZR 4000

Pantera 7000

Code Trouble2 Failure in injector(s).4 Open or short circuit in barometric

pressure sensor.5 Open or short circuit in intake air tem-

perature sensor.6 Open or short circuit in water tempera-

ture sensor.7 Open or short circuit in throttle position

sensor.12 Failure in ignition coil(s).

Code TroubleP0031 O2 Heater Control Circuit LowP0032 O2 Heater Control Circuit HighP0107 Manifold absolute pressure circuit lowP0108 Manifold absolute pressure circuit highP0112 Intake air temp sensor circuit lowP0113 Intake air temp sensor circuit highP0115 Engine coolant temp sensor 1 circuitP0117 Engine coolant temp sensor 1 circuit

lowP0118 Engine coolant temp sensor 1 circuit

high

Code TroubleP0120 Throttle position sensor circuitP0122 Throttle position sensor circuit lowP0123 Throttle position sensor circuit highP0130 O2 sensor circuitP0131 O2 sensor circuit lowP0132 O2 sensor circuit highP0171 System too leanP0172 System too richP0201 Injector circuit/open - cylinder 1P0202 Injector circuit/open - cylinder 2P0203 Injector circuit/open - cylinder 3P0217 Engine coolant over temp conditionP0261 Cylinder 1 injector circuit lowP0264 Cylinder 2 injector circuit lowP0267 Cylinder 3 injector circuit lowP0508 Idle air control system circuit lowP0509 Idle air control system circuit highP0511 Idle air control circuitP0522 Engine oil pressure sensor circuit lowP0523 Engine oil pressure sensor circuit highP0562 System voltage lowP0563 System voltage highP0780 Shift ErrorP1315 Crankshaft Position out of syncP1338 Crankshaft spike detectedP1339 Crankshaft tooth not detectedP1685 Main relay open circuitP1686 Main relay circuit lowP1688 Reverse relay open circuitP1689 Reverse relay circuit lowP1691 Forward relay open circuitP1692 Forward relay circuit lowP1694 Headlight relay open circuitP1695 Headlight relay circuit lowP2228 Barometric pressure sensor A circuit

lowP2229 Barometric pressure sensor A circuit

highP2300 Ignition coil A primary control circuit

lowP2303 Ignition coil B primary control circuit

lowP2306 Ignition coil C primary control circuit

lowU1000 Vehicle not registered or invalid PINU1001 Vehicle not registered and vehicle lim-

its enabledU0155 Lost communication with the ECM

12

Handlebar TiltThe handlebar can be adjusted to theoperator’s preference. To adjust the han-dlebar, use the following procedure:

1. Remove the handlebar cover; thenloosen the eight cap screws securingthe handlebar caps to the riser and theriser to the steering post.

0745-848

0748-378

2. Adjust the handlebar to operator’sdesired position, tighten the capscrews evenly to 15 ft-lb, and checksteering for maximum right/leftturning capabilities.

NOTE: Do not rotate the handlebarto a position that allows air to enterthe brake system.

Exhaust SystemThe exhaust system is designed to reducenoise and to improve the total perfor-mance of the engine. If any exhaust sys-tem component is removed from theengine and the engine is run, severeengine damage will result.

Air-Intake SilencerUsed in conjunction with the fuel intakesystem is a specially designed air-intakesilencer. The purpose of the silencer is toquiet the intake of fresh air. Since the fuelintake system is calibrated with the air-intake silencer in place, the engine mustnever be run with the silencer removed.Performance will not be improved if theair-intake silencer is removed. In con-trast, severe engine damage will occur.

Cooling System

These snowmobiles are equipped with aclosed liquid cooling system for enginecooling. The cooling system should beinspected daily for leakage and damage.Also, the coolant level should be checkeddaily. If leakage or damage is detected,take the snowmobile to an authorizedArctic Cat Snowmobile dealer for ser-vice. If not under warranty, this service isat the discretion and expense of thesnowmobile owner.

When filling the cooling system reser-voir, use an ethylene glycol-based cool-ant/water mixture which will satisfy thecoldest anticipated weather conditions ofyour area in accordance with the coolantmanufacturer’s recommendations.

NOTE: If operating on ice or hard-packed snow conditions, it is recom-mended that Ice Scratchers (p/n 5639-897) be installed and engaged toreduce wear strip wear and engineoverheating.

For checking/filling cooling system, refer toCoolant Level sub-section in the Mainte-nance section.

! WARNINGTighten cap screws according tospecifications to prevent unexpected“movement” of the handlebar duringoperation over rough terrain. DO NOTposition the handlebar so steering(maximum right/left turning capabili-ties) or throttle and brake controlsare affected.

Self-Tapping

Cap Screws

Cap Screws

CAUTIONThese snowmobiles are not designedto be operated in dusty conditions.Operating the snowmobile in dustyconditions will result in severeengine damage.

13

Battery (Pantera 7000)

It is extremely important that the batterybe maintained at full charge at all timesand that the battery connections be cleanand tight. If charging the battery becomesnecessary, refer to Battery sub-section inthe Maintenance section.

Jump-Starting (Pantera 7000)

NOTE: Arctic Cat does not recom-mend jump-starting a snowmobilewith a dead battery but rather toremove the battery, service it, andcorrectly charge it; however, in anemergency, it may be necessary tojump-start a snowmobile. If so, usethe following procedure to carefullyand safely complete this procedure.

1. On the snowmobile to be jump-started,slide any terminal boots away.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, orbulging sides. Leaking or bulgingbattery cases may indicate a frozenor shorted battery.

3. Inspect the vehicle to be used forjump-starting to determine if voltageand ground polarity are compatible.The vehicle must have a 12-volt DC,negative ground electrical system.

4. Move the vehicle to be used for thejump-start close enough to ensurethe jumper cables easily reach; thenset and lock the brakes, shut off allelectrical accessories, and turn theignition switch OFF.

NOTE: Make sure all switches onthe snowmobile to be jump-startedare turned OFF.

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive(red) cable to the positive (+) termi-nal (1) of the dead battery (C) beingcareful not to touch any metal withthe other clamp; then attach theother clamp of the positive (red)cable to the positive (+) terminal (2)of the good battery (B).

CAUTIONAlways turn the ignition switch key tothe OFF position when the snowmo-bile is not being used. Leaving theignition switch in the ON position willresult in discharging the battery andpossible damage to the battery.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns, orblindness as a result of an explosion.Always remove rings and watches.

! WARNINGAny time service is performed on a bat-tery, the following must be observed:keep sparks, open flame, cigarettes, orany other flame away. Always wearsafety glasses. Protect skin and cloth-ing when handling a battery. When ser-vicing a battery in an enclosed space,keep the area well-ventilated.

! WARNINGIf any of these conditions exist, DONOT attempt to jump-start, boost, orcharge the battery. An explosioncould occur causing serious injury.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electricaldamage may occur.

CAUTIONFailure to disconnect electronicaccessories during jump-startingmay cause system damage due topower spikes.

14

0744-527

NOTE: Some jumper cables may bethe same color but the clamps or endswill be color-coded red and black.

7. Attach one clamp of the negativejumper cable (black) to the negative (-)terminal (3) of good battery (B); thenattach the other clamp of the negative(black) jumper cable (4) to an unpaintedmetal surface (A) on the engine orframe well away from the dead batteryand fuel system components.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle torun for several minutes applyingsome charge to the dead battery.

9. Start the snowmobile with the deadbattery and allow it to run for severalminutes before disconnecting thejumper cables.

10. Remove the jumper cables in oppo-site order of hook-up (4, 3, 2, 1). Becareful not to short cables againstbare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the snowmobile again.

Drive Clutch and Driven ClutchThe drive clutch and driven clutch do notrequire lubrication; therefore, no specialmaintenance is required by the snowmo-bile owner except for periodical cleaning.However, the drive clutch and drivenclutch should be disassembled, cleaned,and inspected by an authorized ArcticCat Snowmobile dealer after every 800miles of operation or at the end of thesnowmobiling season whichever occursfirst. This service is at the discretion andexpense of the snowmobile owner.

When operating the snowmobile at highaltitudes, it may be necessary to changecertain component parts of the driveclutch and/or the driven clutch. See anauthorized Arctic Cat Snowmobile dealerfor further information.

Drive Clutch/Driven Clutch AlignmentThe parallelism and the offset between thedrive clutch and driven clutch are set at thefactory. Normally, no adjustment is neces-sary as long as neither the drive clutch northe driven clutch is removed or disassem-bled. However, if premature drive belt wearis experienced or if the drive belt turns over,the drive clutch/driven clutch alignmentmust be checked. Take the snowmobile toan authorized Arctic Cat Snowmobiledealer for this service. If not under war-ranty, this service is at the discretion andexpense of the snowmobile owner.

Fuel PumpThe fuel pump is designed to provide ade-quate amount of gas to the injectors at allthrottle settings. If a fuel delivery problem issuspected, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer. If notunder warranty, this service is at the discre-tion and expense of the snowmobile owner.

! WARNINGNever make the final connection to abattery as a spark could ignite hydro-gen gases causing an explosion ofthe battery resulting in acid burns orblindness.

CAUTIONDO NOT attempt to service the driveclutch and driven clutch. The driveclutch and driven clutch must be ser-viced by an authorized Arctic CatSnowmobile dealer only.

15

Shock AbsorbersStandard Gas

Each shock absorber should be visiblychecked weekly for fluid leakage, cracks orbreaks in the lower case, or a bent plunger.If any one of these conditions is detected,replacement is necessary. Take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for this service. If not underwarranty, this service is at the discretion andexpense of the snowmobile owner.

NOTE: When the snowmobile isoperated in extremely cold weather (-23° C/-10° F or colder), a smallamount of leakage may be present.Unless the leakage is excessive,replacement is not necessary.

Rebuildable Gas

NOTE: The frequency of servicingrebuildable shock absorbers willvary according to the types of condi-tions and terrain the snowmobile hasbeen subjected to. If riding qualitydeteriorates (or seems to be deterio-rating), take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for shock absorber evaluationand/or servicing. This service is atthe discretion and expense of thesnowmobile owner.

Servicing rebuildable shock absorbers isconsidered normal maintenance and is theresponsibility of the owner. Take the snow-mobile to an authorized Arctic Cat Snow-mobile dealer for this service. This serviceis at the discretion and expense of thesnowmobile owner. Kits are available toeither stiffen or soften gas shock valving. Ifchanges in shock valving are desired, seean authorized Arctic Cat Snowmobiledealer. This service is at the discretion andexpense of the snowmobile owner.

Each shock absorber should be visiblychecked weekly for fluid leakage, cracks orbreaks in the lower case, or a bent plunger. Ifany one of these conditions is detected,replacement is necessary. Take the snowmo-bile to an authorized Arctic Cat Snowmobiledealer for this service. If not under warranty,this service is at the discretion and expenseof the snowmobile owner.

NOTE: When the snowmobile isoperated in extremely cold weather(-23° C/-10° F or colder), a smallamount of leakage may be present.Unless the leakage is excessive, ser-vicing is not necessary.

Standard-Lug TrackAccelerated wear strip wear caused byoperating on ice or hard-packed snowconditions is NOT covered under ArcticCat Inc. warranty policy.

Track Studs NOTE: Stud or hooker plate installa-tion will void track and tunnel warranty.

NOTE: Arctic Cat does not recom-mend studding a track with a 1.5inch lug or greater.

NOTE: Stud installation can be per-formed by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic Cat Snow-mobile dealer for this service. Thisservice is at the discretion andexpense of the snowmobile owner.

For proper installation, use the followingprocedure:

1. Using the appropriate stud template(see chart), mark the desired studpattern to be used.

! WARNINGWhen installing studs on a single-plytrack, it is important to use Arctic Cat-approved studs (proper head diame-ter). If approved studs (proper headdiameter) are not used, studs couldtear free of the track causing possibleinjury or even death. Consult anauthorized Arctic Cat Snowmobiledealer for information.

CAUTIONTo prevent tunnel damage from thestuds, Tunnel Protector Kit (p/n 6639-075) must be installed for the ZR4000.

Stud Template ChartModel p/n

ZR 4000 6639-532Pantera 7000 6639-532

16

2. Using the proper-sized stud holedrill bit, drill out the stud holes.

3. Push the stud through the hole frominside the track; then place thedomed support plate and lock nut onthe exposed stud.

4. Using a wrench to secure the stud,tighten the lock nut on the exposed stud.

It is also recommended that wheneverstuds are installed on a track, carbidewear bars should be installed on the skis.Carbide wear bars complement the trackstuds to balance steering control underthese conditions. The length of the car-bide on the wear bars should be propor-tionate to the number of track studs (i.e.small number of track studs — shortlength of carbide...many track studs —long length of carbide). The proper pro-portion between the number of studs andcarbide length on the wear bar will main-tain steering balance.

Reverse Operation (Pantera 7000/ZR 4000 LXR)The reverse function offers the operator theconvenience of being able to back up thesnowmobile rather than having to turn thesnowmobile around by hand. This feature,under most situations, should not be usedto free a stuck snowmobile as it will tend todig the skis deeper into the snow. Alwaysuse minimal speed when operating inreverse and come to a complete stop beforeshifting from either forward to reverse orreverse to forward.

741-438A

NOTE: Correct drive belt tension(deflection) is important for thereverse function to operate properly.If the belt is too tight, difficulty inengaging reverse will be experi-enced (the reverse function willmake up to three attempts to engageinto reverse. If the function is notcompleted after the third attempt, theengine will shut down).

NOTE: Always warm up the enginefor 2-3 minutes prior to shifting intoreverse.

1. To shift into reverse, stop the snow-mobile and allow the engine to idle(under 3000 RPM); then press thereverse button and release. Thereverse selection will be complete.

NOTE: Shift only with the engine atidle RPM and the snowmobile com-pletely stopped. The reverse func-tion will not engage if engine isabove idle RPM.

NOTE: The system will not shiftuntil the button is released.

! WARNINGAlways balance the snowmobile withthe proper proportion between thenumber of studs and carbide lengthon the wear bars. Do not “over drive”conditions; use common sense in alloperating conditions.

CAUTIONDo not use studs that are more than9.525 mm (0.375 in.) longer than thetrack lug height.

! WARNINGDo not operate a snowmobile withloose studs as they may be thrownfrom the track. Always use a shieldedsafety stand whenever performingany maintenance or adjustments.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

17

2. On the ZR 4000 LXR if attempting toshift into reverse at too high engineRPM (above idle RPM), the reversefunction will be cancelled and thecoolant temperature warning icon willflash. This indicates the reverseswitch button was pressed at too highRPM. The operator must reduceengine RPM below 4000 and pressthe button a second time.

NOTE: When reverse is engaged, areverse icon will illuminate in thespeedometer/tachometer and areverse alarm sounds.

3. If the throttle lever is compressedbefore complete reverse engage-ment, the engine may shut down.Always wait for the reverse icon toilluminate and the reverse alarm tosound before backing up.

NOTE: While operating in reverse,a “rev-limiter” will activate at 6000RPM.

4. To shift into forward, stop the snow-mobile and allow the engine to idle(under 3000 RPM); then press thereverse button and release. The for-ward selection will be complete.

5. After shifting from reverse to forward(or from forward to reverse), applythe throttle slowly and evenly to allowthe driven clutch to engage properly.

NOTE: The reverse function is can-celled whenever the engine is shut off.

Adjustable Backrest (Pantera 7000)The backrest is designed for maximumcomfort and safety. When riding double,the backrest must be in the passenger seatposition.

To change the position of the backrest,loosen the two adjuster knobs on either sideof the seat and push the backrest forward orbackward. Tighten both adjuster knobs.

0748-418

When riding single, the backrest can bemoved to the forward seat position.

Removable SeatPantera 7000

NOTE: If additional cargo is beingadded, maximum weight on the snow-mobile (operator/passenger/cargo)should not exceed the maximum limi-tation set for each snowmobile. Seethe chart in the Suspension - Over-load Springs sub-section in the Main-tenance section for details. Also, theoverload springs should be engaged.

CAUTIONNever shift into reverse while thesnowmobile is moving forward as it ishard on the driven clutch torquebracket and the cam rollers.

CAUTIONNever engage the electric starter orpull the recoil starter rope when theengine is running or when operatingin reverse. Damage to the engine and/or either the electric start or recoilstart system will occur.

! WARNINGDo not use high speed when backingup. Control could be lost and injurycould occur.

CAUTIONDo not use high speed when backingup. Damage to the drive belt anddriven clutch components may occur.

CAUTIONAfter reversing in deep powder snowconditions, make sure the snowflapdoes not become “caught up” in thetrack. Track and/or snowflap damagemay occur.

! WARNINGMoving the backrest to the forwardseat position limits the seatingcapacity to one person only.

18

To remove the rear seat, lift up both seatlatches and hold them in that position;then lift and remove the seat. Make sureto disconnect the accessory harness.

0748-449

Release the lever securing the front seatassembly; then lift up and remove thefront seat. Make sure to disconnect theseat heater harness.

0748-419

To install the rear seat base, position thefront of the seat base tabs under the loopsin the seat frame; then press down andsecure using the two seat latches.

SNO-454A

NOTE: On certain models, be sureto connect the accessory harness.

ZR 4000

These snowmobiles are equipped with aremovable seat. To remove the seat,remove the screw from the underside ofthe seat; then lift on the back of the seatand move it up and rearward to remove it.

746-088A

Detachable Hard Storage Cases (Pantera 7000 LTD)These snowmobiles are equipped with twodetachable hard storage cases. To open thecases, slide the side two latches up; thenpress in the key lock and remove from theouter cover. Reverse to close the cover.

0748-394

To remove the cases from the snowmo-bile use the following procedure: Press inthe key lock tabs then lift the lock; thenpress down on the silver tab to unlock thecase from the snowmobile. Carefully tipthe case outward and away from thesnowmobile. Reverse order to install.

! WARNINGMake sure the rear seat is securelylocked in place before carrying a pas-senger or personal injury may result.

19

XM275A

TowingIf the snowmobile is to be towed byanother snowmobile, do not tow usingthe loops in the skis. The tow rope shouldbe attached to the spindles.

20

Operating InstructionsStarting and Stopping EngineIt is imperative that the brake system bechecked for wear and proper operation andthat all safety checks found in the accompa-nying Snowmobile Safety Handbook beperformed before attempting to start theengine. After the engine has been started,check the headlights (high and low beam),taillight, and brakelight to be sure they areworking properly and adjusted correctly.Make sure all lights are clean to providemaximum illumination. The headlight andtaillight must be clean and must be illumi-nated whenever the engine is running.

1. Test the operation of the brake systemby compressing the brake lever. Thebrake lever must feel firm when com-pressed; then while holding the brakelever in the compressed position, mea-sure the distance between the brakelever and the handlebar. The distancemust be greater than 2.54 cm (1 in.).

0745-816

2. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. Thebrake fluid level must be at the highbrake fluid mark in the reservoir.

0745-817

3. If the brake fluid is below the highbrake fluid mark, add Arctic Catapproved DOT 4 brake fluid untilthe fluid is at the recommendedlevel. Install and secure the reservoircover. Do not allow moisture to con-taminate the brake system.

4. Test the throttle control lever bycompletely compressing and releas-ing it several times. The leverMUST return to the idle positionquickly and completely.

5. Move the emergency stop switch tothe UP or RUN position.

6. Insert key into ignition switch; thenrotate key to the RUN position.

NOTE: When a cold engine isbeing started, DO NOT COMPRESSTHE THROTTLE CONTROL LEVER. Ifthe throttle control lever is com-pressed, the engine will not startbecause the fuel/air mixture will betoo lean.

7. On the Pantera 7000, rotate the keyto the START position; then whenthe engine starts, release the key.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Arctic Catapproved brake fluid.

! WARNINGDo not start the engine if the brake sys-tem is not functioning properly. Servicethe brake system or have it properlyrepaired prior to operating the snow-mobile. Serious personal injury or evendeath may occur if the brake system isnot operating properly.

CAUTIONAlways check the coolant level beforestarting the engine.

21

8. On the ZR 4000, pull the recoil handleslowly until resistance is felt; then givea short quick pull. Repeat until theengine starts.

NOTE: In extremely cold weather, pullthe recoil handle slowly two to threetimes to begin the starting procedure.

9. On the ZR 4000 when the enginestarts, allow it to warm up properly.Idle the engine several minutes untilthe engine has reached normal oper-ating temperature. Do not idle theengine for excessively long periodsof time.

10. On the Pantera 7000, a “cold drive-away” function is incorporated withinthe engine. This function is active untilthe engine reaches operating tempera-ture.

11. Flooding — If the engine does notstart but seems ready to start, engagethe brake lever lock; then compressthe throttle control lever fully and tryto start the engine. When the enginestarts, release the throttle control leverimmediately. After the warm-up,release the brake lever lock.

NOTE: On the ZR 4000 if theengine fails to start during theattempt with the throttle control levercompressed, remove the sparkplugs and clean and dry them thor-oughly or install a new set of prop-erly gapped, recommended sparkplugs.

NOTE: On the Pantera 7000 ifspark plugs must be replaced, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forinspection and service. This serviceis at the discretion and expense ofthe snowmobile owner.

12. To shut off the engine, turn the igni-tion key to the OFF position or pushthe emergency stop switch to theDOWN position.

BrakingThe following items are items that theoperator must be familiar with whenoperating this snowmobile and itshydraulic brake system. Important addi-tional information on the proper mainte-nance of the brake system is found in theMaintenance section.

1. Use the brakes wisely. Each time thebrakes are applied in all hydraulicbrake systems (including automotiveapplications), heat is transferred to thebrake fluid. The amount of heat trans-ferred during high speed stops and/orrepetitive use may be high enough toboil the brake fluid and cause thebrakes to either fade or may cause anunexpected loss of brakes.

CAUTIONDo not continuously run the starterfor more than 5 seconds at a time.

CAUTIONTo avoid damaging the recoil starter, DONOT pull the recoil rope to its limit orrelease the recoil handle from anextended position. Allow the rope torewind slowly.

CAUTIONDo not continuously run the starterfor more than 5 seconds at a time.

CAUTIONIt is extremely important that the engineis properly warmed up before subject-ing the engine to high speed operationor heavy loads. The engine should beallowed to idle at least 3-4 minutesbefore it is operated at more than 1/2throttle. In extremely cold conditions,the warm-up time will be longer. Coldseizure and piston scuffing caused byinsufficient warm-up will not be coveredby warranty. Also, do not idle the enginefor excessively long periods of time.

CAUTIONOn the Pantera 7000, always turn theignition switch key to the OFF posi-tion when the snowmobile is notbeing used. Leaving the ignitionswitch in the ON position will result indischarging the battery and possibledamage to the battery.

22

If this occurs, the brake fluid requiresa cool-down period before the brakeswill again function properly. Thiscool-down period will vary dependingupon the ambient air temperature andthe temperature of the brake fluid. Ifloss of brakes has occurred because ofhigh fluid temperatures, do not oper-ate the snowmobile until the cool-down period has expired and brakelever firmness has returned.

2. Be sure to maintain the brake fluid atthe proper level and take care not toget any moisture in the system asmoisture in the brake fluid lowers theboiling point. If the brake fluid is everboiled (by high speed stops or repeti-tive use) or if moisture is allowed toenter the system, it must be changed.Never substitute or mix different typesor grades of brake fluid.

3. Never ride the brake. Even main-taining minimal pressure on thebrake lever will cause the brake padsto drag on the disc and may overheatthe brake fluid.

4. The brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes.NEVER OPERATE THE SNOW-MOBILE WITH THE BRAKELEVER LOCK ENGAGED.

5. Pumping the brake lever is permissi-ble; however, if pumping the brakelever more than twice is necessary toobtain the necessary stopping power,immediately take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the discre-tion and expense of the snowmobileowner.

6. When new brake pads are installed, a“burnishing” process is required. Drivethe snowmobile slowly and compressthe brake lever several times until thepads just start to heat up; then allowthem to thoroughly cool down. Thisprocess stabilizes the pad material andextends the life of the pads.

Emergency StoppingThere are several methods of stopping orslowing the snowmobile under a varietyof situations. Identified in the followingchart are the ways a snowmobile may bebrought to a stop and the effectivenessunder normal conditions.

! WARNINGExcessive, repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wear beforeeach use. Brake loss can result insevere injury or even death.

! WARNINGThe brake lever lock is not a parkingbrake and should not be applied forperiods exceeding 5 minutes. Thebrake lever lock maintains the brakelever in the compressed position andmaintains pressure against the brakedisc; however, after a period of time,the pressure applied to the brake discmay relax below the amount requiredto hold the snowmobile stationary.

Item Function

Emergency Stop Switch

interrupts ignition circuit

Throttle/Ignition Monitor Switch

interrupts ignition circuit

Ignition Switch interrupts ignition circuit

Brake slows the drive system

Tether (RR) interrupts ignition circuit

23

Throttle/Ignition Monitor SwitchThe throttle control is equipped with amonitor switch for safety purposes whichwill stop the engine when a loss of returnspring force occurs. If ice forms in thethrottle system or if there is some othermalfunction of the throttle system result-ing in a loss of return spring force, themonitor switch will stop the engine whenthe throttle control lever is released.

If the snowmobile engine stops abruptlywhen the throttle control lever is releasedand the activation of the monitor switch issuspected, use the following procedure:

1. Rotate the ignition key to the OFFposition.

2. Remove ice and snow from thethrottle system and wait 5-10 min-utes for the engine heat to thaw icefrom the throttle system.

3. Test the throttle control lever bycompressing and releasing it severaltimes. The lever MUST return to theidle position quickly and completely.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, compress the throttlelever slightly (approximately 1/8throttle) and try starting the engine.If the engine now starts and stopswhen the throttle lever is released,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.

4. If the throttle control lever operatesproperly, rotate the ignition key tothe RUN position and go throughnormal starting procedures.

NOTE: If the throttle control leveroperates properly and the enginedoes not start, a malfunctioningmonitor switch may be the problem.Take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor service. If not under warranty,this service is at the discretion andexpense of the snowmobile owner.However, if a dire emergency existswherein the engine must be started,disconnect the throttle monitorswitch located in the right-side han-dlebar control.

NOTE: If disconnection of the throttlemonitor switch is needed to start theengine, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service as soon as possible.If not under warranty, this service is atthe discretion and expense of thesnowmobile owner.

NOTE: The monitor switch is nowbypassed. All other ignition/electricalfeatures (ignition switch, emergencystop switch, headlight, taillight, andbrakelight) will operate properly.

Varying Altitude OperationOperating a snowmobile at varying alti-tudes requires changes in performancecomponents. These changes affect drivetrain components.

! WARNINGIf any malfunction of the throttle sys-tem occurs (such as freezing in fluffysnow) and the monitor switch doesnot shut off the engine, press downon the emergency stop switch IMME-DIATELY to stop the engine. DO NOTstart the engine until the malfunctionin the throttle system has beenlocated and corrected.

! WARNINGIf the throttle control lever does notwork properly, DO NOT ATTEMPT TOSTART THE ENGINE.

! WARNINGUnder no circumstances should dis-connection of the throttle control wir-ing harness be used as a substitutefor the monitor switch during normaloperation of the snowmobile. Per-sonal injury and damage could occurif the throttle system malfunctions orif the operator is unable to stop theengine in an emergency. If the snow-mobile must be operated with a dis-connected throttle control wiringharness, EXTREME CAUTION MUSTBE TAKEN. NEVER EXCEED 10 MPHWITH THE THROTTLE CONTROLWIRING HARNESS DISCONNECTED.

24

For altitude information, see the appro-priate specifications sheet.

NOTE: Just as important as cali-brating the snowmobile for higher alti-tudes is recalibrating the snowmobilewhen going to lower altitudes. Alwaysconsult the altitude decal.

NOTE: Drive train changes can bemade by the snowmobile owner if qual-ified to do so. If the owner does not feelqualified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for this service. This service isat the discretion and expense of thesnowmobile owner.

25

LubricationChain CaseNOTE: The snowmobile must beon a level surface for this procedure.

Check the lubricant level in the chaincase by using the sight glass.

0746-115

NOTE: The correct level is whenthe lubricant is at least halfway up inthe sight glass.

NOTE: Adding lubricant can bedone by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

Pantera 7000, ZR 4000 LXR

NOTE: Make sure the snowmobileis fully shifted into forward.

1. If the lube level is low, remove thethree screws securing the shift actua-tor to the chain case, disconnect theactuator wiring harness, and removethe actuator extension, shift detent,and spring; then add appropriateamount of Arctic Cat SyntheticChain Lube (p/n 6639-539) throughthe shift actuator opening until thelube is halfway up the sight glass.

2. Install the actuator extension andgently rotate counter clockwise tomake sure the shift fork is in the for-ward position.

3. Remove the actuator extension; thenre-install the actuator extensionmaking sure the notch in the exten-sion is directed downward.

4. Install spring into the bottom ofdetent block and install into thechain case cover. The notch in theextension should be lined up withthe notch in the block.

NOTE: Rotate the extension clock-wise approximately 20° making surenot to pull out the extension whenrotating. This is only to aid in theinstallation of the actuator.

5. Install the actuator and secure usingthe existing three torx screws(threads coated lightly with blueLoctite #243). Tighten to 36 in-lb.

6. Connect the harness to the gear posi-tion sensor; then secure the connec-tor to the main harness using a cabletie.

0748-259

7. Start the engine and verify properreverse and forward operation by shift-ing in and out of reverse three times.

NOTE: If excessive build-up ofmoisture or discolored oil isdetected in the chain case, it may benecessary to replace the lube.

ZR 4000 RR

1. If the lube level is low, remove thefill plug from the chain case; thenadd the appropriate amount of ArcticCat Synthetic Chain Lube (p/n 6639-539) in the fill hole. Install the plug.

0746-471

26

To replace the lubricant, use the follow-ing procedure:

1. Remove the side panels, hood, andexhaust resonator.

2. Place a drain pan under the chaincase; then loosen the eleven screwssecuring the chain case cover/oil tankassembly to the chain case housingstarting with the bottom screws first.

3. When the lubricant has completelydrained from the case and the chaincase is cleaned of old oil, install thechain case cover. Tighten the screwsto 12-14 ft-lb.

4. Remove the fill plug; then pour rec-ommended chain lube through theopening until the lubricant is at leasthalfway up in the sight glass.

5. Install and secure the exhaust reso-nator, hood, and side panels.

Rear SuspensionThis procedure should be done every 40operating hours.

NOTE: Arctic Cat recommendsthat Arctic Cat All-Temp Grease (p/n4639-365) be used for this proce-dure.

1. Using Handlebar Stand (p/n 5639-152) or Steering Post Stand (p/n5639-946) or a suitable substitute,lay the snowmobile on its left side.

2. Lubricate all grease fittings with all-temperature grease.

CAUTIONThe correct lubricant to use in thechain case is Arctic Cat SyntheticChain Lube. Any substitute maycause serious damage to the drivesystem.

27

MaintenancePeriodic Maintenance Checklist

Item Interval Page RemarksBrake System Daily 35 Check for binding, leakage, and proper operation;

lever firmness, travel, caliper, disc, and padsCooling System - Liquid Daily 12,30 Check for leakage, damage, obstructions, coolant

levelOil System Daily — Check for leakage, damage, and injection/engine

oil levelEngine Oil (Pantera 7000) 2500 Mi/

Seasonal29 Change oil and filter

Battery Daily 13,33 Check for proper charge and tight connectionsStop Switch Daily — Check for proper operationHoses Daily — Check for damage, leakage, and wearHeadlight & Taillight/Brakelight Daily 46 Check for proper operation and cleanlinessSteering System Daily — Check for proper operation, tightness of bolts, and

bindingThrottle Control System Daily 22 Check for binding, sticking, proper operation, throt-

tle cable tension, and wearDrive Belt Daily

Monthly39 Check for wear, cracks, and fraying

Check length and width dimensionsSki Wear Bars Daily 47 Check for wear and damageElectrical Wiring Weekly — Check for wear, damage, and tight connectionsExhaust System Weekly 12 Check for damage, leakage, and obstructionsNuts, Bolts, Fasteners Weekly — Check tightness Recoil Starter Weekly — Check rope for wear, fraying, and proper operationShock Absorbers Weekly 15,45 Check for fluid leakage and damageSpark Plugs (ZR 4000) Weekly 32 Check center electrode insulator color, carbon,

and gapSpark Plugs (Pantera 7000) 3500 Mi 31 Check center electrode insulator color, carbon,

and gapValve Clearance (Pantera 7000)

5000 Mi/Seasonal

32 Check/adjust

Suspension Weekly 44 Check for damage, loose components, and proper adjustment

Track Tension/Alignment Weekly 42,43 Check/adjust as necessaryWear Strips Weekly 48 Check for wear and damageWires & Cables Weekly — Check for wear, damage, and frayingFuel System - Tank, Pump, In-Line Filter, & Vent Hose

Weekly — Check for damage, wear, obstructions, and leak-age

Fuel Filter (Pantera 7000) 5000 Mi/2 years

— Replace

Air Silencer (ZR 4000) Seasonal — Inspect/cleanChain Case Daily 25 Check lube level and for leakageChain Case - Lubricant Seasonal 25 ReplaceHeat Exchangers Monthly — Check for wear, leakage, and damageDrive Clutch/Driven Clutch Monthly 14,14 Check for damage, binding, and wear/remove

drive belt, clean drive clutch/driven clutch with compressed air, and clean sheaves with suitable parts-cleaning solvent

Front & Rear Suspension Monthly 26, 26 Grease

28

The longevity and safety of the snowmo-bile can be increased by making periodicchecks of the items in the precedingchecklist.

If, at any time, abnormal noises, vibra-tions, or improper working conditions ofany component of this snowmobile aredetected, DO NOT OPERATE THESNOWMOBILE. Take the snowmobileto an authorized Arctic Cat Snowmobiledealer for inspection and adjustment orrepair. If not under warranty, this serviceis at the discretion and expense of thesnowmobile owner.

The snowmobile should be taken to anauthorized Arctic Cat Snowmobile dealerat the end of each snowmobiling seasonfor general inspection and for off-seasonstorage servicing. This inspection andservicing is at the expense of the snow-mobile owner.

Fuel System

In-Line Fuel Filter (Pantera 7000)

Arctic Cat recommends that the in-linefuel filter be replaced every 5000 miles.The in-line fuel filter is located under theupper console. The filter must be clean toallow the fuel hose to transmit theamount of gasoline required.

If the in-line fuel filter is obstructed, gas-oline flow will be restricted; therefore,the filter must be replaced. To removeand install the in-line fuel filter, use thefollowing procedure:

NOTE: Before removing the fuel fil-ter, take note of the filter inlet andoutlet for installing purposes.

NOTE: The fuel filter is located on topof the fuel tank. To access the filter, theaccess panels, hood, seat, and con-soles need to be removed.

XM268

1. Remove the fuel filter from the fuelfilter bracket.

2. Remove the existing hose clampsand discard; then slowly remove thefuel hoses from the fuel filter. Dis-pose of the excess fuel from the fil-ter properly.

3. Inspect the fuel hoses thoroughly forany signs of cracking, cuts, or wearpoints.

4. Place new hose clamps on thegasline hoses; then press the hosesfully onto the fuel filter making surethe inlet and outlet oriented cor-rectly. Secure the new hose clampsusing Fuel Hose Clamp Tool (p/n0644-545).

5. Secure the new fuel filter to the fuelfilter bracket; then start the engineand inspect the fuel hoses and filterfor any signs of leaks.

0746-802

! WARNINGWhenever any maintenance orinspection is made on the fuel systemin which there may be fuel leakage,there should be no welding, smoking,open flames, etc., in the area.

! WARNINGSince the fuel supply hose may beunder pressure, always wear safetyglasses; then remove the hose slowlyto release the pressure. Place anabsorbent towel around the connec-tion to absorb the fuel.

29

Gasoline Additives

Fuel de-icer can be used for all models.Also, periodic use of an injector cleanerfor the ZR 4000 is recommended espe-cially in the last tank of gasoline beforestorage. Arctic Cat Fuel Stabilizer (p/n0436-907) should also be added to thelast tank of gasoline before storage.

Fuel Pickup Valves

These models are equipped with fuelpickup valves in the gas tank. If ever thereis a restricted fuel flow and a pickup valveis suspected, take the snowmobile to anauthorized Arctic Cat Snowmobile dealerfor this service. If not under warranty, thisservice is at the discretion and expense ofthe snowmobile owner.

Checking/Adding Engine Oil (ZR 4000)

1. Park the snowmobile on a level surface.

2. Remove the right-side access panel.

3. Remove the fastener securing theright side of the lower console to theskid plate.

4. Verify if oil is visible in the sight glasslocated on the side of the oil tank.

5. If oil is not present within the sightglass, remove the oil tank cap andadd the appropriate oil through thefiller neck making sure to fill only tothe bottom of the filler neck.

Checking Engine Oil Level (Pantera 7000)NOTE: The engine must be atoperating temperature before check-ing the oil level or an incorrect oillevel will result.

1. Park the snowmobile on a level sur-face; start the engine and let it idle andwarm up until the fan on the radiatorturns on, or if the snowmobile wasoperated, allow the engine to idle forapproximately 30 seconds.

2. Shut the engine off; then remove theright-side access panel and verify oilis visible at least halfway up in thesight glass.

SNO-244A

3. If oil is not visible halfway up in thesight glass, add recommendedengine oil until oil is visible half-way up the sight glass.

Changing Engine Oil/Filter (Pantera 7000)

NOTE: Recycle or properly dis-pose of the used engine oil.

NOTE: The access panels and hoodmust be removed for this procedure.

1. Park the snowmobile on a level sur-face; then start the engine and allowit to warm up for 5-10 minutes, or ifthe snowmobile was operated, allowthe engine to idle for approximately30 seconds. Shut the engine off.

2. Remove the torx-head screws andthe access plate from beneath thesnowmobile.

3. Place a drain pan beneath the engine oilpan drain plug; then remove the plugand allow the oil to drain completely.

CAUTIONCare must be taken not to over-fill theoil tank.

CAUTIONIf the engine and oil are not at operat-ing temperature, the oil will not bevisible in the sight glass. Tip thesnowmobile to the right at a 45°angle; then check to see if oil is pres-ent in the sight glass.

CAUTIONCare must be taken not to over-fill thereservoir with oil.

! WARNINGCare must be taken if a hot drain plug isremoved by hand. Burning could occur.

30

XM125A

4. Using Oil Filter Wrench (p/n 0644-551), loosen (but do not remove) theoil filter and allow the oil to drainfrom the filter into the drain pan;then remove the filter.

5. Apply a light coat of fresh engine oilto the seal of the new oil filter.

6. Install the new oil filter by turningthe oil filter by hand until the sealhas contacted the oil filter mountingsurface; then tighten the oil filter to12 ft-lb. Remove the drain pan.

7. Install the engine oil drain plug witha new gasket; then tighten to 7.2 ft-lb.

8. Remove the four torx-head screwssecuring the right-side footrest to thetunnel and the support; then with adrain pan in position, remove thedrain plug from the oil tank.

746-121A

NOTE: To aid in draining the oilfrom the oil tank, position a funnelbetween the tank and the opening ofthe tunnel running board.

9. After the oil has drained completely,install the drain plug with a new O-ring and tighten to 16 ft-lb.

10. Pour the recommended engine oilinto the oil tank.

11. Without starting the engine, placethe handlebar emergency stopswitch to the RUN position and theignition switch to the ON position.

NOTE: If the warning icon does notilluminate, take the snowmobile toan authorized Arctic Cat Snowmo-bile dealer for service. If not underwarranty, this service is at the dis-cretion and expense of the snowmo-bile owner.

12. If the warning icon illuminates (fromstep 11), start the engine. The warningicon should go out within five seconds.If it does, proceed to step 13.

NOTE: The engine may need to bestarted 2-3 times before it will stayrunning.

NOTE: If the warning icon does notgo out, shut the engine off immedi-ately and repeat step 11; then placethe ignition switch to the ON posi-tion and repeat step 12. If the warn-ing icon does not go out, take thesnowmobile to an authorized ArcticCat Snowmobile dealer for service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

13. Shut the engine off; then add oil tothe oil tank until oil is visible half-way up in the sight glass.

NOTE: If the oil and engine are notat operating temperature, the oillevel may read too low. Always makesure the engine is at operating tem-perature before checking the oil.

14. Install the access plate and torx-headscrews beneath the snowmobile; theninstall the hood and access panels.

Coolant LevelZR 4000

NOTE: Use a good quality, ethyl-ene glycol-based, automotive-typecoolant.

NOTE: Always check the coolantlevel with the engine cold.

31

Locate the coolant tank behind theexpansion chamber. If the coolant needsto be added, fill the coolant tank up to thecold fill line located on the tank.

747-545A

Pantera 7000

Locate the filler neck located above theresonator; then remove the coolant capfrom the filler neck. Verify that the coolantis at the bottom of the tab in the filler neck.

0747-547

NOTE: Under normal conditionschecking only the overflow tank(located above the drive clutch) isacceptable. Only if this tank does nothave coolant should the operatorhave to remove the hood and checkthe level at the filler neck.

Locate the coolant tank above the driveclutch; then remove the plug from thecoolant tank. Add coolant to the full levelon the tank. Install the plug.

0747-766

Spark PlugsNOTE: Always use the recom-mended spark plugs in the engine.See the appropriate specificationssheet for correct spark plug gap.

Varying terrain conditions and operatingusage may require spark plugs of a differ-ent heat range. For example, sustainedcross-country riding will usually requirecolder heat-range spark plugs while trailriding or other continual slow speedoperation will usually require hotter heat-range spark plugs.

Removing/Installing

Pantera 7000

NOTE: Spark plug maintenancemay be done by the snowmobileowner if qualified to do so. If theowner does not feel qualified, takethe snowmobile to an authorizedArctic Cat Snowmobile dealer forthis service. This service is at thediscretion and expense of the snow-mobile owner.

CAUTIONAfter operating the snowmobile forthe initial 5-10 minutes, stop theengine, allow the engine to cooldown, and check the coolant level.Add coolant as necessary.

CAUTIONIf the coolant is below the neck and ifcoolant has been added, immediatelyinspect for leakage and/or damage. Ifleakage or damage is detected, takethe snowmobile to an authorized Arc-tic Cat Snowmobile dealer for ser-vice. If not under warranty, thisservice is at the discretion andexpense of the snowmobile owner.

CAUTIONIf adjusting spark plug gap is neces-sary, do not use the center electrodeas a leverage point. Damage to theplug may occur.

32

NOTE: For this procedure, thehood and side panels must beremoved.

1. Remove the spark plug end caps.

2. Using a 3/8-in. drive ratchet,adapter, and a 5/8-in. spark plugsocket, remove the spark plugs.

NOTE: Prior to installing the sparkplugs, check the gap between theelectrode and ground strap. The clear-ance should be 0.7-0.8 mm (0.028-0.031 in.).

3. Install the spark plugs. Tighten to 96in.-lb.

4. Install the spark plug end caps.

5. Install the hood and access panels.

ZR 4000

1. Remove the springs securing theexpansion chamber to the exhaustmanifold and resonator.

2. Move the expansion chamber out ofthe way to access the spark plugs.

3. Remove the spark plug caps fromthe plugs.

4. Using a spark plug wrench, removethe plugs.

5. Install the plugs and finger-tighten.

6. Tighten the spark plugs to 19 ft-lb;then install the spark plug caps.

7. Place the expansion chamber intoposition and secure to the exhaustmanifold and resonator with thesprings.

8. Install the hood.

Checking

To see if the spark plugs being used are ofthe proper heat range (after the snowmo-bile has been operated under normal driv-ing conditions), remove the spark plugsand examine the condition of the centerelectrode insulator of each spark plug.

AO352A

A. TAN or LIGHT BROWN insula-tor indicates correct spark plugs(heat range).

B. LIGHT GRAY or WHITE insula-tor indicates over-heating of theengine. This condition is caused bya too lean condition or incorrectspark plugs (heat range too hot).

C. BLACK insulator indicates fuelin the combustion chamber is notburning completely. This condi-tion is caused by a too rich con-dition, too much oil, or incorrectspark plugs (heat range too cold).

NOTE: If the center electrode insu-lators are light gray, white, or black,oil-injection pump synchronization,and ignition timing are correct, differ-ent heat-range spark plugs may benecessary. Authorized Arctic CatSnowmobile dealers have detailedspark plug information. Consult adealer before changing spark plugs,as incorrect heat-range spark plugscould cause poor engine performanceor engine damage.

Valve Clearance (Pantera 7000)After 25,000 miles or prior to seasonalstorage, valve clearance should bechecked and adjusted as necessary.

CAUTIONIf a spark plug is light gray, white, orblack and another is tan or lightbrown, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service. Ifnot under warranty, this service is atthe discretion and expense of thesnowmobile owner.

33

NOTE: Take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for inspection and service.This service is at the discretion andexpense of the snowmobile owner.

Battery (Pantera 7000)These standard and sealed batteries afterbeing in service require regular cleaningand recharging in order to deliver peakperformance and maximum service life.The following procedures are recom-mended for cleaning and maintainingstandard and sealed batteries. Alwaysread and follow instructions providedwith battery chargers and battery prod-ucts.

NOTE: Battery maintenance maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

To remove and charge the battery, use thefollowing procedure:

1. Remove the rear and front seat.

2. Remove the negative battery cableand ground wire; then remove thepositive cable.

NOTE: For installing purposesprior to removing the battery, notethe routing and securing locations ofthe cables and harness wires.

3. Remove the two lock nuts securingthe battery bracket/solenoid to theseat-base; then move the bracket upand out of the way and remove thebattery.

4. Thoroughly wash the battery withsoap and water; then using a wirebrush, clean the battery posts andcable ends removing all corrosivebuildup. Replace damaged cables orcable ends.

NOTE: If battery posts or cableends have a build-up of white/greenpowder residue, apply water andbaking soda to neutralize acid; thenflush off with warm soapy water.

5. Using a multimeter, test battery voltage.The meter must read no less than 12.5DC Volts for a fully charged battery.

CAUTIONIt is critical that the checking/adjust-ing valve clearance be done at therecommended intervals or severeengine damage may occur.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns,or blindness as a result of an explo-sion. Always remove rings andwatches. Any time service is per-formed on a battery, the followingmust be observed: keep sparks, openflame, cigarettes, or any other flameaway. Always wear safety glasses.Protect skin and clothing when han-dling a battery. When servicing a bat-tery in an enclosed space, keep thearea well-ventilated.

! WARNINGBattery posts, terminals, and relatedaccessories contain lead and leadcompounds, chemicals known to thestate of California to cause cancerand reproductive harm. Wash handsafter handling.

CAUTIONMake sure to disconnect the acces-sory plug for the rear seat and thefront seat heater connector prior toremoving the seats.

! WARNINGAvoid spillage and contact with skin,eyes, and clothing.

CAUTIONDo not charge the battery while it is inthe snowmobile with the battery ter-minals connected.

CAUTIONDo not remove seal strip on a sealedbattery.

! WARNINGBattery acid is harmful if it contactseyes, skin, or clothing. Care must betaken whenever handling a battery.

34

NOTE: At this point if the meterreads as specified, the battery maybe returned to service (see step 9).

6. If the meter reads less than specifiedvoltage, charge the battery using thefollowing guidelines.

A. When using an automatic batterycharger, always follow the char-ger manufacturer’s instructions.

B. When using a constant-currentbattery charger, use the follow-ing Battery Charging Chart.

NOTE: If the battery voltage is 11.5DC Volts or less, some chargers may“cut off” and fail to charge. If thisoccurs, connect a fully chargedbooster battery in parallel (positive topositive and negative to negative) fora short period of time with the chargerconnected. After 10-15 minutes, dis-connect the booster battery leavingthe charger connected and the char-ger should continue to charge. If thecharger “cuts off,” replace the battery.

7. After charging the battery for thespecified time, remove the batterycharger and allow the battery to sitfor 1-2 hours.

8. Connect the multimeter and test thebattery voltage. The meter shouldread no less than 12.5 DC Volts. Ifthe voltage is as specified, the bat-tery is ready for service.

NOTE: If voltage in step 8 is belowspecifications, charge the battery anadditional 1-5 hours; then retest. Thebattery is ready for service.

9. Place the battery into position in thesnowmobile; then coat the batteryposts and cable ends with a lightcoat of multi-purpose grease.

10. Secure the red positive cable to thepositive terminal on the batteryusing a cap screw, lock washer, anda flat washer. Tighten securely.

11. Secure the main black negativecable and the small black negativecable to the battery using a capscrew, lock washer, and a flatwasher. Tighten securely.

NOTE: Assure the harness wires andcables are routed properly as notedduring removing battery procedure.

XM167A

CAUTIONNever exceed the standard chargingrate.

! WARNINGAn overheated battery could explodecausing severe injury or death.Always monitor charging times andcharge rates carefully. Stop chargingif the battery becomes very warm tothe touch. Allow it to cool beforeresuming charging.

Battery Charging Chart(Constant-Current Charger)

Battery Voltage

(DC)

ChargeState

Charge Time Required (at 1.5-

2.0 Amps)

12.5 (mini-mum)

100% None

12.2-12.4 75%-99% 3-6 hours

12.0-12.2 50%-74% 5-11 hours

11.0-11.9 25%-49% 13 hours (minimum)

11.5 or less 0-24% 20 hours (minimum)

CAUTIONBefore installing the battery, makesure the ignition switch is in the OFFposition.

CAUTIONConnecting cables in reverse (posi-tive to negative and negative to posi-tive) can cause serious damage tothe electrical system.

35

12. Install the battery bracket/solenoidand tighten the two lock nuts to 105in.-lb; then install the seat andsecure with the torx-head screw.Tighten securely.

NOTE: On the LTD prior to lower-ing and securing the seat, connectthe seat heater harness connector.

Fuses (Pantera 7000)

Fuses protect the snowmobile electricalsystem from overloading. If electricalparts in the snowmobile are not working,the system may have been overloaded andcaused a blown fuse. Before repairing orreplacing any electrical part, check theappropriate fuses. If a fuse blows (opens acircuit), all the parts of the snowmobilethat use that circuit will not work.

Once which fuse to check has been deter-mined, perform the following steps:

1. Locate the fuse block and removethe fuse block cover.

NOTE: The fuse block is behindthe coolant overflow bottle.

XM124A

NOTE: There are spare fusesbeneath the fuse block cover.

2. Remove the suspected fuse.

NOTE: Fuse function descriptionsare next to the fuse contacts in thefuse block.

3. Look through the clear side of thefuse to see if the element inside isburned or separated. If it is, the fuse isblown and should be replaced with afuse of the correct amperage rating.

4. Install the fuse panel cover and closethe access panel.

Even after replacing a fuse, it may con-tinue to blow if the cause of the overloadis not determined. If the fuse continues toblow, take the snowmobile to an autho-rized Arctic Cat Snowmobile dealer forservice. If not under warranty, this ser-vice is at the discretion and expense ofthe snowmobile owner.

Brake SystemArctic Cat recommends that the brakesystem (brake lever, fluid reservoir, hose,caliper, pads, and brake disc) be checkeddaily for fluid leakage, wear, or damageand for proper operation. Also, the brakefluid level must be checked every timebefore starting the engine. The brakefluid must be visible in the sight glass.

Checking/Adding Brake Fluid

1. With the brake fluid reservoir in alevel position and the coverremoved, check the fluid level. Thebrake fluid level must be at the highbrake fluid mark in the reservoir.

! WARNINGAlways replace a fuse with one hav-ing the same specified amperage rat-ing. Using a fuse with a higher ratingcan cause severe wire damage andcould start a fire.

! WARNINGDO NOT operate the snowmobilewhen the brake lever lock is engagedor when any component in the brakesystem is damaged, worn, oradjusted improperly. If the snowmo-bile is operated and the brake systemis not functioning properly, severepersonal injury could result.

36

745-817A

2. If the brake fluid is not visible in thesight glass, remove the reservoir coverand add Arctic Cat approved DOT 4brake fluid until the fluid is at the rec-ommended level. Install and secure thereservoir cover. Do not allow moistureto contaminate the brake system.

Changing Brake Fluid

The brake fluid must be changed on a reg-ular basis and whenever the brake fluid hasbeen overheated or contaminated. Thebrake fluid should be changed every 1000miles or at the end of the snowmobilingseason, whichever occurs first. Take thesnowmobile to an authorized Arctic CatSnowmobile dealer for this service. Thisservice is at the discretion and expense ofthe snowmobile owner.

Checking Brake Lever Travel

Before each use, check the brake levertravel using the following procedure:

1. Compress the brake lever fully.

NOTE: Do not pump the brakelever as it will produce an inaccuratereading.

2. Measure the distance between thebrake lever and the handlebar. Thedistance must be greater than 2.54cm (1 in.).

0745-816

3. If the resultant distance is less thanspecified, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for service. If not under war-ranty, this service is at the discretionand expense of the snowmobile owner.

Bleeding Brake System

If the brake lever feels spongy whenapplied, the brake system may need to bebled. To bleed the brake, use the follow-ing procedure:

NOTE: The brake system may bebled by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

1. Remove the reservoir cover and (ifnecessary) fill the reservoir to thehigh brake fluid mark with ArcticCat approved DOT 4 brake fluid.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

! WARNINGDo not overfill the brake fluid reser-voir. Overfilling the reservoir maycause the brake system to hydrauli-cally lock. Use only Arctic Catapproved DOT 4 brake fluid. Neversubstitute or mix different types orgrades of brake fluid. Brake loss canresult. Brake loss can result in severeinjury or even death.

! WARNINGDo not operate the snowmobile if thecompressed distance between thebrake lever and the handlebar is lessthan 2.54 cm (1 in.). Brake loss mayoccur. Brake loss can result in severepersonal injury.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

37

2. Slide a piece of flexible tubing overthe ball of the bleeder valve anddirect the other end into a container.

XM145A

3. Slowly compress the brake leveruntil maximum pressure is attained;then hold the lever in the com-pressed position to maintain pres-sure. Open the bleeder valve torelease the fluid and air. When thefluid stops, close the bleeder valve;then release the brake lever.

4. Repeat step 3 until the brake fluidflows free of air bubbles.

NOTE: It may be necessary to refillthe reservoir during the bleedingprocess. Never allow the brake fluidto go below the low brake fluid markin the reservoir.

5. When the brake fluid is free of all airand the brake lever feels firm whencompressed, fill the reservoir to thehigh brake fluid mark; then install andsecure the cover. Remove the tubefrom the bleeder valve.

Checking/Changing Brake Pads

The condition of the brake pads must bechecked daily and changed if worn ordamaged. To check and change the brakepads, use the following procedure:

NOTE: The brake pads may bechanged by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

NOTE: When installing new brakepads, always install them as a set.Never install just one pad or usebrake pads which have been used inanother snowmobile.

1. Remove the brake fluid reservoir cover;then remove most of the brake fluidfrom the reservoir. Install the cover.

NOTE: The above procedure willallow room for the fluid from the cali-per when the pistons are pushedinto the caliper for installing newbrake pads. Replacing the cover willprevent fluid spillage.

2. Open the left-side access panel.

3. Remove the torx-head screws secur-ing the brake shield to the belt guardmount; then remove the cap screwssecuring the brake shield to thebrake caliper.

4. Carefully move the shield out of theway; then remove the hairpin clipsecuring the brake pads to the cali-per assembly.

5. Using a pair of pliers, pull the outerbrake pad out of the caliper assembly.

PC013

! WARNINGUse only Arctic Cat approved DOT 4brake fluid. Any substitute may resultin a loss of brakes.

CAUTIONBrake fluid is highly corrosive. Do notspill brake fluid on any surface of thesnowmobile.

38

NOTE: Changing one pad at a timewill prevent one piston from pushingout the other piston from the caliper.

6. Measure the thickness of the brakepad. The brake pad thickness mustbe greater than 5.0 mm (0.20 in.). Ifthe brake pad thickness is less thanspecified, replacement of both padsis necessary.

PC011A

7. Using a flat-blade tool, slowly andcarefully push the piston into thecaliper.

8. Position the outer brake pad into thecaliper; then install the hair-pin clipinto the caliper assembly.

9. Repeat steps 5-8 for the inner pad;then secure the pad with the hairpinclip.

10. Remove the reservoir cover andremove the remaining fluid; then fillthe reservoir with fresh fluid andinstall the cover.

11. Pump the brake lever to ensure cor-rect positioning of the brake pads andproper brake lever travel; then release.

NOTE: If brake lever travel is notwithin specification, bleed the brakesystem.

12. Remove the reservoir cover and fillthe reservoir (if necessary) to theproper level with fresh brake fluid;then install the cover.

13. Secure the brake shield, the drivenclutch (tightened to 20 ft-lb); thenclose and secure the left-side accesspanel.

NOTE: When new brake pads areinstalled, a “burnishing” process isrequired (see Burnishing Brake Padssub-section).

Burnishing Brake PadsAfter changing brake pads, the new brakepads must be burnished to achieve fullbraking effectiveness. Braking distancewill be extended until brake pads areproperly burnished.

To properly burnish the brakes, use fol-lowing procedure:

1. Choose an area sufficiently large tosafely accelerate to 30-40 mph andto brake to a stop.

NOTE: This procedure can also beaccomplished using a shielded jackstand.

2. Accelerate to 30-40 mph; then com-press brake lever to decelerate to a stop.

NOTE: Lightly apply the brakelever to come to an easy stop; do notover-apply brakes or “lock up” thetrack.

3. Repeat procedure 10-15 timesallowing some cooling betweenstops.

NOTE: Do not repeat too soon ortoo aggressively as to get the brakedisc “red hot.”

NOTE: This procedure stabilizesthe pad material and extends the lifeof the pads.

Chain Tension (Pantera 7000)

1. Remove the right side access cover;then remove the exhaust assembly.

2. Loosen the jam nut.

3. Turn the chain tension adjustmentbolt clockwise until it is finger tight;then loosen it 1 1/2 turns.

! WARNINGDo not attempt sudden stops or putyourself into a situation where a sud-den stop will be required until thebrake pads are properly burnished.

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0747-831

4. While holding the bolt with a wrench,tighten the jam nut to 18 ft-lb.

5. Install the exhaust assembly with anew gasket.

6. Install the right-side access cover.

NOTE: Check that the harness isinstalled correctly.

Drive BeltThe drive belt transfers power from thedrive clutch to the driven clutch. If thebelt is worn, cracked, or stretched, maxi-mum power will not be transmitted andthe belt could also fail and therefore mustbe replaced. Periodic checks (at leastonce a month under normal usage) of twodrive belt specifications are essential.

1. Measure the outside circumferenceof the drive belt. The belt should bewithin the recommended range incircumference (see appropriate spec-ifications sheet).

2. Measure the outside width of thedrive belt. The belt should be withinthe recommended range in width.

3. Check the belt for cracking, fraying, etc.

If any of the specifications or conditionsare unsatisfactory, replace the drive belt.

NOTE: Drive belts should be pur-chased from an authorized Arctic CatSnowmobile dealer, as Arctic Cat drivebelts are made to exact specificationsand of quality material. Belts made byother manufacturers may not be of thesame specifications or quality and,therefore, usage could result in poorperformance and premature belt failure.

NOTE: Before starting the snowmo-bile in extremely cold temperatures,the drive belt should be removed andwarmed up to room temperature.Once the drive belt is at room temper-ature, install the drive belt.

Also, new drive belts have a break-in periodof approximately 25 miles. After installing anew drive belt, drive the snowmobile for 25miles at 3/4 throttle or less. By revving theengine up and down (but not exceeding 60mph), the exposed cord on the side of a newbelt will be worn down. This allows thedrive belt to gain its optimum flexibility andwill extend drive belt life.

Checking/Adjusting Drive Belt Deflection (Pantera 7000/ZR 4000 LXR)

SNO-276A

The drive belt must have the proper fit inthe drive clutch and driven clutch. Tocheck for proper drive belt fit, use thefollowing procedure.

1. Place a straightedge on the top of thedrive belt. The straightedge shouldreach from the drive clutch to the topof the driven clutch.

NOTE: Make sure the drive belt isall the way out in the driven clutchbefore checking drive belt deflection.

CAUTIONNever run the engine with the drivebelt removed. Excessive revving ofthe engine could result in seriousengine damage and drive clutch fail-ure.

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2. Using a stiff ruler centered betweenthe drive clutch and driven clutch,push down on the drive belt justenough to remove all slack and notethe amount of deflection. The deflec-tion should be within the range of28.5-31.8 mm (1 1/8-1 1/4 in.).

3. To correct drive belt deflection,remove the sheave adjuster from theclutch, remove or add shim washers tothe adjuster, and install the adjuster.

NOTE: Adding shim washers willdecrease belt deflection and removingshim washers will increase belt deflec-tion. Available shim washers from Arc-tic Cat are p/n 0648-714 (0.090 in.) - oneincluded in the tool kit, p/n 0648-715(0.030 in.), and p/n 0648-716 (0.060 in.).

NOTE: Removing/adding shim wash-ers may be done by the snowmobileowner if qualified to do so. If the ownerdoes not feel qualified, take the snow-mobile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

Removing Drive Belt (Pantera 7000/ZR 4000 LXR)NOTE: Changing a drive belt can bedone by the snowmobile owner if qual-ified to do so. If the owner does notfeel qualified, take the snowmobile toan authorized Arctic Cat Snowmobiledealer for this service. This service isat the discretion and expense of thesnowmobile owner.

1. Turn ignition key to the OFF positionand wait for all moving parts to stop.

2. Set the brake lever lock.

3. Open the left-side access panel.

4. Remove the cap screw, lock washer,washer, and sheave adjuster from theend of the driven clutch; then removethe sheave adjuster from the capscrew.

0743-395

NOTE: Each time the driven clutchcap screw is removed, the hole in thedriven shaft should be cleaned freeof any Loctite residue.

NOTE: Verify the shims and O-ringare not removed from the adjuster.

5. Remove the lock washer and flatwasher from the cap screw and reversethe sheave adjuster.

6. Install the cap screw into the drivenclutch; then tighten the cap screw untilthe movable sheave opens far enough toallow the belt to be removed.

7. Remove the drive belt from the drivenclutch first; then from the drive clutch.

NOTE: Before installing the drivebelt, use a suitable cleaning solvent tothoroughly clean the sheaves.

Installing Drive Belt (Pantera 7000/ZR 4000 LXR)NOTE: If a new drive belt is beinginstalled, see Drive Belt Break-In sub-section in the General Informationsection.

1. Place the drive belt (so the part num-ber can be read and the arrows are fac-ing the front of the snowmobile)between the sheaves of the driveclutch first; then between the sheavesof the driven clutch.

CAUTIONBefore securing the driven clutch, besure the rollers are up against thetorque bracket or damage to the back-side cams may occur.

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2. Install the cap screw, lock washer,washer, and sheave adjuster back intothe driven clutch. Tighten the capscrew (apply a few drops of blue Loc-tite #243 to the threads) to 20 ft-lb.

3. Install the left-side access panel.

4. Release the brake lever lock.

Removing Drive Belt (ZR 4000 RR)

1. Set the brake lever lock; thenremove the left-side access panel.

2. Using Drive Belt Deflection Tool (p/n 0644-424), thread the tool clock-wise into the driven clutch until themovable sheave opens far enough toremoving the drive belt.

743-067B

Installing Drive Belt (ZR 4000 RR)

1. Place the belt (so the part numbercan be read) between the sheaves ofthe drive clutch.

2. With the sheaves fully apart, roll thebelt over the stationary sheave.

3. With the drive belt properly posi-tioned in the drive clutch and drivenclutch, turn the belt tool counter-clockwise, release the brake leverlock, and roll the belt back and forthto allow the driven clutch sheaves tofully close.

4. After the belt is installed properly,install the left-side access panel.

Checking/Adjusting Deflection (ZR 4000 RR)Drive belt length, condition, and deflec-tion are all important for peak perfor-mance. To check and adjust drive beltdeflection, use the following procedure.

1. With the engine off; remove the left-side access panel.

2. Make sure the drive belt is sitting atthe top of the driven clutch sheaves.

3. Place a straightedge on the top of thedrive belt. The straightedge shouldreach from the drive clutch to the topof the driven clutch.

4. Using a stiff ruler centered betweenthe drive clutch and driven clutch,push down on the drive belt justenough to remove all slack and notethe amount of deflection. Thedeflection should be approximately15.9-22.2 mm (5/8-7/8 in.).

NOTE: The amount of deflectionshould be experimented with ortested to obtain best start-line per-formance.

NOTE: Push down on the belt withthe ruler only until the bottom of thebelt flexes upward; then read theamount of deflection.

5. To correct drive belt deflection,loosen the jam nut on the belt widthadjuster on the stationary sheave.

6. Using an Allen wrench, adjust theset screw as needed.

NOTE: Turning the set screwclockwise increases distancebetween the sheaves (increases beltdeflection measurement); turningthe set screw counterclockwisedecreases distance between thesheaves (decreases belt deflectionmeasurement).

! WARNINGNever operate the snowmobile with-out the belt guard/access panelsecured in place.

42

Track TensionTrack tension is directly related to theoverall performance of the snowmobile. Ifthe track is too loose, it may slap againstthe tunnel causing wear or it may “ratchet”on the track drive sprockets. If extremelyloose, the idler wheels may climb over thetrack lugs forcing the track against the tun-nel causing the track to “lock.”

Arctic Cat recommends that the track ten-sion be checked daily during the first 300miles of operation and once a week there-after and adjusted according to need. Thetrack will stretch and take a “set” duringbreak-in. Track deflection must be main-tained within the recommended range.

Checking Track Tension

1. Remove excess ice and snow buildupfrom the track, track drive sprockets,and the inside of the skid frame.

2. Elevate the snowmobile on ashielded safety stand high enough touse a spring scale.

3. At mid-point of the track (on the bot-tom side), hook a spring scale around atrack clip; then pull down on the scaleto the recommended pressure. Measurethe deflection (distance) between thebottom of the wear strip and the insidesurface of the track clip. Compare themeasurement with the chart.

743-191A

Adjusting Track Tension

NOTE: To ensure proper track ten-sion adjustment, perform all adjust-ments on both sides of thesnowmobile.

1. Loosen the idler wheel axle capscrews.

0745-811

0748-447

2. If the deflection (distance betweenthe bottom of the wear strip and theinside surface of the track clip)exceeds specifications, tighten theadjusting bolts to take up excessiveslack in the track.

3. If the distance between the bottom ofthe wear strip and the inside surfaceof the track clip is less than specified,loosen the adjusting bolts to increasethe slack in the track.

! WARNINGTrack tension must be properly main-tained. Personal injury could result ifa track is allowed to become exces-sively loose.

! WARNINGDO NOT attempt to check or adjusttrack tension with engine running.Turn ignition key to the OFF position.Personal injury could result from con-tact with a rotating track.

Track Tension

ZR 4000 - 129” 2 in. @ 20 lb

Pantera 7000 - 146” 2 in. @ 20 lb

43

4. Check track alignment.

5. After proper track tension isobtained, tighten the idler wheelaxle cap screws to 34 ft-lb; thentighten the adjusting bolts securelyagainst the axle.

NOTE: Since track tension andtrack alignment are interrelated,always check both even if only oneadjustment seems necessary.

Track AlignmentProper track alignment is obtained whenthe rear idler wheels are equal distancefrom the inner track drive lugs. Excessivewear to the idler wheels, drive lugs, andtrack will occur if the track is improperlyaligned. Arctic Cat recommends that thetrack alignment be checked once a weekor whenever the track tension is adjusted.

Checking Track Alignment

1. Remove excess ice and snow buildupfrom the track, track drive sprockets,and the inside of the skid frame.

2. Position the tips of the skis against awall; then using a shielded safetystand, raise the rear of the snowmo-bile off the floor making sure thetrack is free to rotate.

3. Start the engine and accelerateslightly. Use only enough throttle toturn the track several revolutions.SHUT ENGINE OFF.

NOTE: Allow the track to coast to astop. DO NOT apply the brakebecause it could produce an inaccu-rate alignment condition.

4. When the track stops rotating, checkthe relationship of the rear idlerwheels and the inner track drive lugs.If the rear idler wheels are centeredbetween the inner track drive lugs, noadjustment is necessary.

0745-809

0748-448

CAUTIONAlways maintain track tension withinrecommended specification.

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

! WARNINGMake sure the ignition key is in theOFF position and the track is notrotating before checking or adjustingtrack alignment. Personal injurycould result if contact is made with arotating track.

! WARNINGThe tips of the skis must be posi-tioned against a wall or similarobject.

! WARNINGDO NOT stand behind the snowmo-bile or near the rotating track. NEVERrun the track at high speed when thetrack is suspended.

44

5. If the idler wheels are not centeredbetween the inner track drive lugs,an adjustment is necessary.

Adjusting Track Alignment

1. On the side of the track which has theinner track drive lugs closer to the rearidler wheel, loosen the idler wheelaxle cap screw; then rotate the adjust-ing bolt clockwise 1 to 1 1/2 turns.

0745-811

0748-447

2. Check track alignment and continueadjustment until proper alignment isobtained.

NOTE: Make sure correct tracktension is maintained after adjust-ing track alignment.

3. After proper track alignment isobtained, tighten the idler wheelaxle cap screw to 34 ft-lb; thentighten the adjusting bolts securelyagainst the axle.

4. Field test the track under actual con-ditions.

5. After the field test, check the align-ment of the track. If additional adjust-ment is necessary, repeat AdjustingTrack Alignment procedure.

SuspensionThe suspension should be adjusted forthe operational needs and riding prefer-ence of the operator.

The front shock springs determine theamount of ski pressure and the reactionof the front suspension to rough terrain.The amount of ski pressure can also bechanged by adjusting the length of theskid frame front arm limiter straps.

The rear springs influence the load carry-ing capability of the snowmobile andshould be adjusted for the weight and rid-ing preference of the operator.

Adjusting Fox Air Shocks (ZR 4000 RR)

NOTE: It is recommended to moni-tor the air pressure in the air shocksonce every month.

NOTE: Adjusting air shocks maybe done by the snowmobile owner ifqualified to do so. If the owner doesnot feel qualified, take the snowmo-bile to an authorized Arctic CatSnowmobile dealer for this service.This service is at the discretion andexpense of the snowmobile owner.

! WARNINGAlways make sure the adjusting boltsare snug against the axle and theidler wheel cap screws are tightenedto specifications. Failure to do socould cause the track to becomeextremely loose and, under someoperating conditions, allow the idlerwheels to climb over the track lugsforcing the track against the tunnelcausing the track to “lock.” If a track“locks” during operation, severe per-sonal injury could result.

45

The air shocks are individually adjustablefor the terrain conditions and drivingstyle of the operator. The shocks are pre-set at the factory (see chart) as an initialsetting; however, it is possible to “finetune” the shocks to match the operator’sweight, riding style, and terrain condi-tions.

NOTE: Adding air pressure willincrease the air spring force; reduc-ing air pressure will decrease airspring force.

Checking and adjusting air pressure mustbe done at riding temperature (outside).Also, it is advisable to check air pressurewhen the outside temperature variesmore than 25°.

Adjusting Front (Ski) Shock Springs (Pantera 7000/ZR 4000 LXR)

The front (ski) shock springs are individ-ually adjustable for the terrain conditionsand driving style of the operator. Thespring adjuster nut has been set at the fac-tory so the correct amount of threads areexposed between the adjuster nut and thethreaded shock body as an initial setting.Additional ski pressure can be obtainedby tightening the spring tension; ski pres-sure can be decreased by relaxing springtension.

NOTE: Equal adjustments shouldbe maintained on both sides of thesnowmobile.

Front (ski) shock spring pre-load adjust-ment is accomplished by loosening theadjuster nut locking collar (B) from theadjuster nut (A) and using the SpringAdjuster Tool from the tool kit, rotatingthe adjuster nut in whichever direction isdesired. Tighten the locking collaragainst the adjuster nut.

0745-159

Adjusting Rear Spring Pre-LoadProper adjustment of rear spring pre-loadis necessary to get the most desirableride. The chart is designed to help in set-ting up rear spring pre-load; however,riding style is the single greatest factor indetermining rear spring requirements.

NOTE: These cam position set-tings are suggestions only. Personalriding style will greatly influencecam position settings. Spend time todetermine setting preferences.

Rear spring pre-load adjustment is accom-plished by rotating the adjusting cams.Position 3 provides the stiffest ride, andposition 1 is for the light driver or slow-speed trail riding. Position 2 is for theaverage operator under normal conditions.Always rotate the cam from the lighterposition to the heavier position.

741-450A

Front Shock (Ski) Rear Arm Shock80 psi (Main Chamber)200 psi (Evol Chamber)

N/ARider Weight (lb) Cam Position

Up to 180 1

180-240 2

Over 240 3

CAUTIONNever force the adjustment camsfrom the low position to the highposition. Cam damage may occur.

46

To rotate an adjusting cam, use the sparkplug wrench from the tool kit. Rotate thewrench until the cam is in the desiredposition. To stiffen the ride, rotate the camso as to raise the spring end. Make theappropriate adjustment on the other cam.

Overload Springs (Pantera 7000)When either carrying a heavy load or rid-ing 2-up, the overload springs should beengaged by rotating the spring tensionblocks to the UP position. The spring ten-sion blocks lock in an over-center posi-tion when engaged.

NOTE: Arctic Cat recommendsthat the overload springs beengaged whenever a load on thesnowmobile (operator/passenger/cargo) exceeds 136 kg (300 lb).

To either engage or disengage the springtension blocks, use a spark plug socketand a screwdriver to adjust the springblock to the desired position. Make sureboth spring blocks are in the same posi-tion (either engaged or disengaged).

744-457A

LightsFor the correct headlight bulb and/or tail-light/brakelight LED, see the appropriatespecifications sheet.

Removing and Installing Taillight/Brakelight

These models are equipped with an LEDtaillight/brakelight. If the LED fails, itmust be replaced. To remove and installthe LED, use the following procedure.

1. Disconnect the taillight harness con-nector.

2. Remove the torx-head screws secur-ing the taillight.

3. Connect the taillight harness connec-tor; then secure the taillight to thebracket with the torx-head screws.

Removing/Installing Headlight Bulb

NOTE: The bulb portion of headlightis fragile. HANDLE WITH CARE. Whenreplacing the headlight bulb, the bulbassembly must first be removed fromthe housing. Do not touch the glassportion of the bulb. If the glass istouched, it must be cleaned with a drycloth before installing.

1. Disconnect the headlight harnessconnector from the bulb; thenremove the rubber grommet fromthe headlight housing.

2. Rotate the bulb retainer counter-clockwise until it unlocks from thehousing; then remove the bulb.

0746-096

3. Install the bulb and retainer; thenrotate the retainer clockwise until itproperly locks in place.

4. Install the rubber grommet; thenconnect the headlight harness con-nector to the bulb.

CAUTIONThere are weight limitations for thesesnowmobiles. If additional cargo isbeing added, maximum weight on thesnowmobile (operator/passenger/cargo) should not exceed the maxi-mum limitation set for each snowmo-bile. See chart for details. Also, theoverload springs should be engaged.

Maximum Weight Limitations

Pantera 7000 170 kg 375 lb

47

5. Check headlight aim.

Adjusting Headlight Aim

The headlight can be adjusted for verticalaim of the HIGH/LOW beam. The geo-metric center of HIGH beam zone is to beused for vertical aiming.

1. Position the snowmobile on a levelfloor so the headlight is approxi-mately 8 m (25 ft) from an aimingsurface (wall or similar surface).

NOTE: There should be an “aver-age” operating load on the snowmo-bile when adjusting headlight aim.

2. Measure the distance from the floorto midpoint of the headlight.

3. Using the measurement obtained instep 2, make a horizontal mark onthe aiming surface.

4. Make a vertical mark which intersectsthe horizontal mark on the aiming sur-face directly in front of the headlight.

5. Engage the brake lever lock and startthe engine. Move the headlight dimmerswitch to the HIGH beam position. DONOT USE LOW BEAM.

6. Observe the headlight beam aim.Proper aim is when the most intensebeam is centered on the vertical mark 5cm (2 in.) below the horizontal markon the aiming surface.

0745-813

7. Adjust the headlight using the adjust-ing screw on the backside of the head-light using a 4 mm swivel socket andlong extension until correct aim isobtained. Shut the engine off; then dis-engage the brake lever lock.

0746-807

Ski Wear BarsThe ski wear bar is a replaceable barattached to the underside of the ski. Thepurpose of the wear bar is to assist inturning the snowmobile, to minimize skiwear, and to maintain good steering con-trol. If the snowmobile is operated pri-marily in deep snow, ski wear bar wearwill be minimal; however, if the snow-mobile is operated on terrain where thesnow cover is minimal, the ski wear barwill wear faster. To maintain positivesteering characteristics, Arctic Cat rec-ommends that the ski wear bars bechecked before each use and replaced ifworn beyond 1/2 of the original diameter.Ski wear bars are available from anauthorized Arctic Cat Snowmobiledealer.

Removing Ski Wear Bars

1. Using Front End Lift (p/n 5639-151), elevate the front of the snow-mobile.

2. Remove the lock nuts securing thewear bar to the ski.

! WARNINGDo not operate the snowmobileunless headlight beam is adjustedproperly. An incorrectly adjustedbeam will not provide the operatorthe optimum amount of light.

! WARNINGOperating the snowmobile withexcessively worn ski wear bars mayresult in a loss of steering control.

48

0743-185

3. Remove the wear bar from the ski.

Installing Ski Wear Bars

1. Move the wear bar into position onthe bottom of the ski.

NOTE: If installing a double-offsetwear bar for normal steering capabil-ities, the carbide edge should bedirected to the inside of the ski.

2. Align the wear bar studs with theholes in the ski; then install the locknuts. Tighten to 11-15 ft-lb.

Adjusting Ski StanceNOTE: Local laws and/or regula-tions as to maximum width of the skistance on these snowmobiles maybe applicable. Always comply withthe maximum width laws and/or reg-ulations when adjusting ski stance.

NOTE: Ski stance can be increased/decreased by 2.5 cm (1.0 in.).

1. Place the front of the snowmobile ona support stand.

2. Remove the cotter pin; then removethe slotted nut and cap screw secur-ing the ski assembly to the spindle.Remove the ski. Account for therubber damper, inserts, and washers.

3. To increase ski stance, place skistance spacer to the outside of thespindle and adjust the damper.

0746-797

4. To decrease ski stance, place skistance spacer to the inside of thespindle and adjust the damper.

0746-796

5. Apply an all-temperature grease to thenon-threaded portion of the capscrew; then slide the cap screwthrough the ski accounting for the rub-ber damper, inserts, and washers.

NOTE: Install the cap screw so the nutwill be located to the inside of the ski.

6. If using the existing nut, apply red Loc-tite #271 to the threads of the capscrew; then tighten the nut to 45 ft-lb.

7. Place new cotter pin into the ski capscrew and spread the pin.

8. Repeat procedure for the other ski.

Rail Wear StripsArctic Cat recommends that the wear stripsbe checked weekly and replaced as neces-sary. Measure the wear strips at 25.4 cm(10 in.) intervals. Wear strips must be 10.7mm (0.42 in.) thick or thicker.

49

0743-189

If wear strip measurements are less thanspecified, replacement of both wear stripsis necessary to prevent premature trackclip wear and possible track damage.Take the snowmobile to an authorizedArctic Cat Snowmobile dealer for thisservice. This service is at the discretionand expense of the snowmobile owner.

Each time a new set of wear strips areinstalled, they should be tempered. Tem-per the wear strips by driving the snow-mobile for approximately a mile on ahard pack trail; then immediately driveinto deep snow and allow the wear stripsto cool. Repeat the procedure (warmingup the wear strips; then cooling themdown) two or three times.

NOTE: The rail wear strips will wearrapidly if the snowmobile is operatedon terrain on which the snow cover isminimal. Loose snow is required tocool and lubricate the wear strips andprevent accelerated wear.

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Performance TipsOperating a high performance snowmo-bile requires a special attention that is notrequired by a low performance snowmo-bile. Often, a minor adjustment willresult in a large increase in performance.This section is intended to highlightminor conditions that adversely affectperformance and the adjustments neededto correct them. Be sure, however, tothoroughly read and understand thisentire manual especially the section onspark plugs, track tension and alignment,and suspension.

DRIVE BELT — This link between theengine and drive train is often the mostneglected component. The drive belt musthave the proper fit in the drive clutch anddriven clutch. Proper fit is when the topsurface of the drive belt is flush with thetop or up to 1/16 in. higher than the drivenclutch sheaves (with the sheaves fullyclosed). If drive belt deflection is abovespecification, the snowmobile will bog andlack power at engagement and will have aslower maximum speed. For good perfor-mance, proper belt deflection is critical. Tocorrect this condition, first determine if thedrive belt is within specifications andreplace if worn or too long. Always runthe drive belt in the same direction.Installing the drive belt so the part num-ber can be read will ensure that the drivebelt is always run the same direction.

DRIVE BELT DEFLECTION — Drivebelt length, condition, and deflection areall important for peak performance. Tocheck and adjust drive belt deflection,remove the belt guard; then use the fol-lowing procedure.

NOTE: It may be necessary toremove a shim washer from betweenthe driven clutch sheaves to allowthe driven clutch to close tighter.Adding shim washers will decreasebelt deflection and removing shimwashers will increase belt deflection.Available shim washers from ArcticCat are p/n 0648-714 (0.090 in.) - oneincluded in the tool kit, p/n 0648-715(0.030 in.), and p/n 0648-716 (0.060in.).

NOTE: Removing/adding shimwashers may be done by the snow-mobile owner if qualified to do so. Ifthe owner does not feel qualified,take the snowmobile to an autho-rized Arctic Cat Snowmobile dealerfor this service. This service is at thediscretion and expense of the snow-mobile owner.

1. Turn the engine off; then open theleft access panel.

2. Make sure the drive belt is sitting atthe top of the driven clutch sheaves.

3. Place a straightedge on top of thedrive belt. The straightedge shouldreach from the driven clutch to thetop of the driven clutch.

4. Using a stiff ruler centered betweenthe drive clutch and driven clutch,push down on the drive belt justenough to remove all slack. Note theamount of deflection on the ruler atthe bottom of the straightedge. Thedeflection should be at 1 1/4 in.

SNO-276A

NOTE: Push down on the belt withthe ruler only until the bottom of thebelt flexes upward; then read theamount of deflection.

5. To correct drive belt deflection,remove the sheave adjuster from theclutch, remove or add shim washersto the adjuster, and install theadjuster.

NOTE: Adding shim washers willdecrease belt deflection; removingshim washers will increase beltdeflection.

6. Install the access panel.

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DRIVE CLUTCH AND DRIVENCLUTCH — Keeping the drive clutchand driven clutch clean should be the pri-mary consideration of the operator. Thedrive clutch and driven clutch can becleaned of any drive belt accumulationusing compressed air. The sheaves can becleaned using a clean cloth and parts-cleaning solvent.

DRIVE CLUTCH/DRIVEN CLUTCHOFFSET — If premature drive belt wearis experienced or if the drive belt turnsover, offset must be checked. Also, offsetmust be checked whenever either thedrive clutch or driven clutch is serviced.

NOTE: For checking offset, it isnecessary to use Clutch AlignmentBar (p/n 0644-428) to obtain a driveclutch/driven clutch offset of 1.485in. This special tool can be pur-chased from an authorized ArcticCat snowmobile dealer.

To check offset, use the following proce-dure.

1. Open the left-side access panel andunlock the quarter-turn screw secur-ing console; then move the consoleup and out of the way.

2. Install the clutch Alignment Bar (p/n0644-428) between the drive clutchsheaves.

3. Allow the bar to rest on the driveclutch shaft and against the outsideedge of the driven clutch stationarysheave.

NOTE: The alignment bar mustextend beyond the front edge of thedrive clutch.

4. With the bar against the outside edgeof the driven clutch stationarysheave at points A and B, the barshould just clear the inside edge ofthe stationary sheave of the driveclutch and rest on the stationaryshaft at point C with a maximum0.76 mm (0.030 in.) clearance atpoint C. At this point, measurementbetween points A and C should be37.72 mm (1.485 in.) with a maxi-mum 0.76 mm (0.030 in.) clearance.If the bar either will not clear theinside edge or is more than the spec-ified amount (see chart), the offsetmust be corrected.

0746-808

NOTE: If the offset is out of speci-fication, take the snowmobile to anauthorized Arctic Cat Snowmobiledealer for drive system evaluationand/or servicing. This service is atthe discretion and expense of thesnowmobile owner.

52

Preparation for StoragePrior to storing the snowmobile, it must beproperly serviced to prevent corrosion andcomponent deterioration. An authorizedArctic Cat Snowmobile dealer should per-form this service; however, the owner/operator can perform this service ifdesired. This service is at the discretionand expense of the snowmobile owner. Toprepare the snowmobile for storage, ArcticCat recommends the following procedure:

1. Clean the seat cushion with a dampcloth and a Vinyl Protectant.

2. Clean the snowmobile thoroughly byhosing dirt, oil, grass, and other foreignmatter from the skid frame, tunnel,hood, and belly pan. Allow the snow-mobile to dry thoroughly. DO NOT getwater into any part of the engine.

NOTE: On the Pantera 7000,change the engine oil; then proceedto step 5.

3. Place the rear of the snowmobile upon a shielded safety stand.

4. Spray an Engine Storage Preserverinto the intakes until the engineexhaust starts to smoke heavily oruntil the engine starts to drop inRPM. Turn engine off.

5. Plug the exhaust system outlet witha clean cloth.

6. With the ignition switch in the OFFposition:

A. Disconnect the high tensionleads from the spark plugs; thenremove the plugs, connect themto the leads, and ground them onthe cylinder heads.

B. Pour 29.5 ml (1 fl oz) of SAE#30 petroleum-based oil intoeach spark plug hole and pull therecoil starter handle slowly about10 times.

C. Install the spark plugs and con-nect the high tension leads.

7. Fill the gas tank to its rated capacity;then add Arctic Cat Fuel Stabilizer(p/n 0436-907) to the gas tank fol-lowing directions on the containerfor the stabilizer/gasoline ratio.Tighten the gas tank cap securely.

8. Remove the drive belt from the driveclutch/driven clutch. Lay the belt ona flat surface or slide it into a card-board sleeve to prevent warping ordistortion during storage.

9. Clean and inspect the drive clutchand driven clutch.

10. Apply light oil to the upper steeringpost bushing and shafts of the shockabsorbers.

11. Lubricate the rear suspension, spin-dles, and steering arms with all-tem-perature grease.

12. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely. Make sure all rivets hold-ing the components together aretight. Replace all loose rivets.

13. Clean and polish the hood, console,and chassis with Cat Cleaner (p/n4639-371). DO NOT USE SOL-VENTS. THE PROPELLANTWILL DAMAGE THE FINISH.

CAUTIONDo not do steps 3-5 on the Pantera7000; severe engine damage couldresult.

CAUTIONDo not do step 6 on the Pantera 7000;severe engine damage could result.

CAUTIONNever crank the engine over withoutgrounding the spark plugs. Damageto coils and/or CDI/ECM may result.

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NOTE: On Pantera 7000 models,disconnect the battery cables makingsure to disconnect the negative cablefirst; then clean the battery posts andcables. Charge the battery.

14. If possible, store the snowmobileindoors. Raise the track off the floorby blocking up the back end makingsure the snowmobile is secure.Loosen the track adjusting bolts toreduce track tension. Cover thesnowmobile with a machine cover ora heavy tarpaulin to protect it fromdirt and dust.

15. If the snowmobile must be stored out-doors, position the snowmobile out ofdirect sunlight; then block the entiresnowmobile off the ground makingsure the snowmobile is secure. Loosenthe track adjusting bolts to reducetrack tension. Cover with a machinecover or a heavy tarpaulin to protect itfrom dirt, dust, and rain.

CAUTIONSealed batteries require charging ifleft for extended non-start periods.Arctic Cat recommends trickle charg-ing once a month. Follow the manu-facturer’s instructions and cautions.

CAUTIONAvoid storing in direct sunlight andusing a plastic cover as moisture maycollect on the snowmobile causingcorrosion.

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Preparation after StorageTaking the snowmobile out of storageand correctly preparing it for another sea-son will assure many miles and hours oftrouble-free snowmobiling. Arctic Catrecommends the following procedure:

1. Clean the snowmobile thoroughly.Polish the exterior of the snowmobile.

2. Clean the engine. Remove the clothfrom the exhaust system. Checkexhaust system and air-intakesilencer for obstructions.

3. Inspect all control wires and cablesfor signs of wear or fraying. Replaceif necessary. Use cable ties or tape toroute wires and cables away fromhot or rotating parts.

4. Inspect the drive belt for cracks andtears. Check belt specifications.Replace if damaged or worn.

NOTE: If the old belt is worn but inreasonable condition, retain it withthe snowmobile as a spare in case ofemergency.

5. Inspect all fuel hoses and oil hosesfor deterioration or cracks; replace ifnecessary. Make sure all connectionsare tight; then on the ZR 4000, fill theoil-injection reservoir with C-Tec2engine oil.

NOTE: After prolonged storage ofthe ZR 4000, Arctic Cat recommendsone tankful of 100:1 gas/oil mixture beused in conjunction with the oil-injec-tion system to ensure proper lubrica-tion.

6. Inspect the spark plugs. Replace,gap, or clean as necessary.

7. Verify the condition of and theadjustment of the throttle cable.

8. Tighten all nuts, bolts, and capscrews making sure all nuts, bolts,and cap screws are tightenedsecurely.

9. If not done during preparation forstorage, lubricate the rear suspen-sion, spindles, and steering armswith all-temperature grease.

10. Check the coolant level and all cool-ant hoses and connections for deteri-oration or cracks. Add properlymixed coolant as necessary.

11. On Pantera 7000 models, charge thebattery until fully charged; then con-nect the battery cables making sureto connect the positive cable first.Test the electric start system.

12. Inspect the entire brake system, allcontrols, headlight, taillight, brake-light, ski wear bars, and headlightaim; adjust or replace as necessary.

13. Adjust the track to the proper tensionand alignment.

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U.S. EPA Emission Control Statement/Warranty Coverage (U.S. Only)

STATEMENT/WARRANTYArctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Arctic Cat snowmobiles are designed, built, and equipped to conform to all U.S. EPA EmissionControl Regulations. Please read the following information completely.

Your authorized Arctic Cat snowmobile dealer will repair or replace any defective emission-relatedcomponent at no cost to you during the warranty period. You may have non-warranty service performedby any repair establishment that uses equivalent components. The regulations provide significant civilpenalties for tampering that causes your snowmobile to no longer meet U.S. EPA emission standards.

Arctic Cat further warrants that the engine and its emission-related components are free from defects inmaterials or workmanship that could cause the engine to fail to comply with applicable regulationsduring the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contactyour local authorized Arctic Cat snowmobile dealer.

WARRANTY PERIODThe emission warranty period for this snowmobile begins on the same date as the standard warrantycoverage and continues for 30 months or 2500 miles, whichever comes first.

COMPONENTS COVEREDThe emissions warranty covers major emissions control components and emission-related componentslisted as follows:

Engine Management and Sensors Fuel/Air SystemBarometric Pressure Sensor Fuel InjectorsCamshaft Position Sensor Fuel Pressure RegulatorEngine Control Module (ECM) Fuel PumpEngine Coolant Temperature Sensor Carburetor(s)Intake Air Temperature Sensor Manifold Absolute Pressure SensorAir Bypass ValveOxygen SensorThrottle Position Sensor Crankcase Ventilation System

ISC Valve

Ignition System Miscellaneous Items Used in Aforementioned SystemsIgnition Coil ConnectorsKnock Sensor System SwitchesCrankshaft Position Sensor GrommetsExhaust Temperature Sensor ClampsCapacitive Discharge Ignition (CDI) Module HosesMagneto Pick-Up TiesSpark Plugs Gaskets

Wiring

OWNER'S RESPONSIBILITIESThe owner of any snowmobile warranted under this Arctic Cat Emission Control Statement isresponsible for the proper maintenance and use of the snowmobile in accordance with Arctic Cat’srecommendations in the Operator's Manual.

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NOTES

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Change of Address, Ownership, or Warranty Transfer

Arctic Cat Inc. keeps on file the current name and address of theowner of this vehicle. This allows Arctic Cat to reach the currentowner with any important safety information which may benecessary to protect customers from personal injury or propertydamage. Please make sure a copy of this form is completed andreturned to Arctic Cat Inc. if you move or if the vehicle is sold toanother party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty,fill out this form completely; then return a copy of this form toArctic Cat Inc. Arctic Cat will then process the application andissue warranty for the balance of the time remaining of theoriginal warranty. Warranty coverage is only available in thecountry in which the original retail purchase occurs to theoriginal retail purchaser resident in that country or to atransferee resident in that country of the balance of theremaining warranty.

Address Change

Ownership Change

Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name ________________________________________

Address ______________________________________

City/State (Province)/Zip Code (Postal Code) __________

Phone # ( ) __________________________________

Year and Model _________________________________

Vehicle Identification Number (VIN) _________________

Fold Back Once

CHANGE OF ADDRESS/OWNERSHIP

ARCTIC CAT INC.PRODUCT SERVICE AND

WARRANTY DEPT.P.O. BOX 810

THIEF RIVER FALLS, MN 56701

PlaceStampHere

Warranty Procedure/Owner Responsibility

At the time of sale, an Owner Registration form is to be completed by the sellingdealer and consumer. The receipt of the registration form by Arctic Cat is a condi-tion precedent to warranty coverage. It is the selling dealer’s responsibility to retainand/or submit the appropriate copies of the form to the appropriate place(s) to initi-ate warranty coverage.

The dealer will furnish to the consumer a signed copy of the form which must bepresented to the dealer when requesting warranty service. The registration form isthe consumer’s proof of ownership and warranty eligibility. The form is usedby the dealer to validate the warranty claim. Retain your copy of the form andkeep it in a safe place.

When warranty repair is suspected, the snowmobile should be taken to the sellingdealer, who has the primary responsibility to perform warranty repairs. Subject tothe limitations set forth in the Limited Warranty, in the event the selling dealer hasceased to do business, you have moved, or you are in a location away from yourselling dealer, warranty may be performed by any authorized Arctic Cat Snowmo-bile dealer.

The authorized Arctic Cat Snowmobile dealer will examine the snowmobile or partto determine if, in his opinion, a warrantable condition exists. If a warrantable con-dition appears to exist, the dealer will repair or replace, at Arctic Cat’s option, freeof charge, including any related labor costs, all parts that are found to be warrant-able and any other parts which the warrantable part caused to be damaged. You, theconsumer, will then be asked to sign a warranty form to ensure Arctic Cat that thewarranty work was actually performed.

It is the consumer’s responsibility to maintain and service the snowmobile in accor-dance with Arctic Cat’s recommendations in the Operator’s Manual. To protectyourself and your snowmobile, follow all safety and service tips. Arctic Cat willNOT warrant repairs required as a result of not performing standard operatormaintenance, storage procedures, and service as outlined in the Operator’sManual.

Should you have any questions concerning the warranty, contact an authorized Arc-tic Cat Snowmobile dealer.

Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (218) 681-8558

Printed in U.S.A. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2260-436Phone: (218) 681-9851 - U.S./(204) 982-1656 - Canada

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