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2002 Arctic Cat snowmobile service and shop manual

Models covered in this manual:

Arctic Cat Inc.

  • ZR 440 Sno Pro
  • ZR 500
  • ZR 600
  • ZR 800
  • ZR 900
  • ZL 550
  • ZL 600
  • ZL 800
  • Mountain Cat 600
  • Mountain Cat 800
  • Mountain Cat 1000
  • Panther 370
  • Panther 440
  • Panther 570
  • Bearcat Wide Track
  • Bearcat 550

Production year(s): 2002

File specifications

File size: 473.30 MB
File type: ZIP
Language: English (some of our manuals are multi-language)

Printable: Yes
Estimated download time: 9.69 Minutes
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Product Information

Table of Contents

General Information

  1. Snowmobile Identification
  2. Recommended Gasoline and Oil
  3. Break-In Procedure
  4. Genuine Parts
  5. High Altitude Operation
  6. Drive Chain Lubrication (120 cc)
  7. Preparation For Storage
  8. Preparation After Storage
  9. After Break-In Checkup (100 Miles)
  10. After Break-In Checkup Checklist
  11. Torque Conversions
  12. Tightening Torque (General Bolts)
  13. Fraction/Decimal Conversion Chart
  14. Drill Bit Sizes (Number) Chart
  15. MM/In. Conversion Chart
  16. Servicing Symbols

Engine

  1. Engine Removal
  2. Engine Installation
  3. Cylinder Head Removal
  4. Cylinder Head Installation
  5. Valve Clearance Adjustment
  6. Timing Chain Tensioner
  7. Camshaft Removal
  8. Camshaft Installation
  9. Piston Removal
  10. Piston Installation

Fuel System

  1. Fuel Pump Removal
  2. Fuel Pump Installation
  3. Carburetor Removal
  4. Carburetor Installation
  5. Throttle Body Removal
  6. Throttle Body Installation

Electrical System

  1. Battery Charging
  2. Battery Testing
  3. Alternator Removal
  4. Alternator Installation
  5. Ignition Coil Testing
  6. Ignition Coil Replacement
  7. Spark Plug Testing
  8. Spark Plug Replacement

Drive System

  1. Drive Belt Removal
  2. Drive Belt Installation
  3. Chaincase Removal
  4. Chaincase Installation
  5. Drive Shaft Removal
  6. Drive Shaft Installation

Suspension

  1. Front Suspension Removal
  2. Front Suspension Installation
  3. Rear Suspension Removal
  4. Rear Suspension Installation
  5. Shock Absorber Removal
  6. Shock Absorber Installation

Brakes

  1. Brake Pad Removal
  2. Brake Pad Installation
  3. Brake Disc Removal
  4. Brake Disc Installation
  5. Brake Caliper Removal
  6. Brake Caliper Installation

Steering

  1. Handlebar Removal
  2. Handlebar Installation
  3. Steering Column Removal
  4. Steering Column Installation
  5. Tie Rod Removal
  6. Tie Rod Installation

Cooling System

  1. Radiator Removal
  2. Radiator Installation
  3. Coolant Drain
  4. Coolant Fill
  5. Thermostat Removal
  6. Thermostat Installation

Body

  1. Seat Removal
  2. Seat Installation
  3. Windshield Removal
  4. Windshield Installation
  5. Hood Removal
  6. Hood Installation

Troubleshooting

  1. Engine Problems
    • Engine won't start
    • Engine stalls
  2. Electrical Problems
    • Battery won't charge
    • Lights not working
  3. Drive System Problems
    • Drive belt slipping
    • Chaincase noise
  4. Suspension Problems
    • Rough ride
    • Suspension noise
  5. Brake Problems
    • Poor braking performance
    • Brake noise
  6. Steering Problems
    • Loose steering
    • Steering noise
  7. Cooling System Problems
    • Overheating
    • Coolant leaks
  8. Body Problems
    • Loose panels
    • Broken parts

Maintenance Schedule

  1. Daily Checks
    • Oil level
    • Coolant level
  2. Weekly Checks
    • Brake pads
    • Drive belt
  3. Monthly Checks
    • Suspension
    • Steering
  4. Annual Checks
    • Full service
    • Detailed inspection

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