1999 Arctic Cat Z, ZL, Panther, Bearcat, Thundercat, Powder Special, and ZR Snowmobile Service Manual Volumes I & II

This Arctic Cat Service Manual, Volumes I and II, was published by the Product Service and Warranty Department, Arctic Cat Inc. It covers 1999 Z, ZL, Panther, Bearcat, Thundercat, Powder Special, and ZR models, plus Pantera, ZRT, Triple Touring, and the 60 cc single-cylinder engine.

Both volumes are combined in one 647-page PDF.

• Engine repair: Model-specific removal, teardown, inspection, assembly, and installation for single-, twin-, and triple-cylinder engines, plus water-pump and recoil-starter service.

• Fuel systems: VM- and TM-style carburetor service and synchronization, batteryless EFI troubleshooting, and oil-injection pump testing, synchronization, and bleeding.

• Electrical diagnosis: CDI and ignition-sensor tests, digital 3-D ignition TPS adjustment, electric-start troubleshooting, and ignition, main-harness, and hood-harness wiring diagrams.

• Drivetrain and brakes: Drive clutch and driven pulley repair, alignment, chain-case service with and without reverse, hydraulic brake bleeding, and mechanical brake adjustment.

• Steering and suspension: AWS steering service, ski alignment, FasTrack skid-frame repair, track adjustment, and rebuilding IFP, quick-adjust, and remote-reservoir shocks.

• Technical references: Assembly schematics, component torque tables, wear limits, clearances, fill quantities, and electrical test specifications.

Arctic Cat prepared this two-volume manual for service personnel familiar with the operation and construction of the snowmobile's components.

Engine Service and Assembly

Engine procedures distinguish fan-cooled twins, 440 LC/550 cc engines, 500/580/600 cc twins, 700 cc twins, and 600/800/1000 cc triples. Internal work covers crankcase separation, reed assemblies, crankshaft inspection, and balancer-shaft timing where applicable.

The engine-related sections add axial-fan belt service, thermostat inspection, and engine pressure testing. For the 700 cc engine, assembly cautions explain how incorrect oil-pump drive alignment can crack the pump mounting flange.

Printed pages 2-52 and 2-98 are absent from the engine section's page sequence. Engine specifications also appear later in the Engine Information section.

Carburetors and Batteryless EFI

Separate Mikuni VM- and TM-style procedures address choke settings, throttle synchronization, and mixture adjustment. Oil-injection service extends to pump output and check-valve testing.

Batteryless EFI diagnosis covers LED trouble codes, stored-fault checks with the EFI Analyzer (p/n 0644-212), fuel-pressure testing, and stator/ECU output checks. The EFI Component Voltage/Resistance charts provide air- and water-temperature sensor reference data.

Always ensure work areas are well-ventilated and fuel systems are safely depressurized before starting mechanical work to prevent hazardous vapor buildup.

Ignition and Chassis Electrical Systems

TPS adjustment applies to the 700/800/1000 cc digital 3-D ignition systems. For a failed batteryless EFI TPS, the manual specifies replacement of the complete throttle-body assembly.

Ignition tests distinguish fan-cooled engines from liquid-cooled twins and triples. Model-to-harness indexes and wire-color/function tables help identify the correct circuit before tracing a fault. Chassis tests cover brake-light switches, lighting controls, and hand/thumb warmers.

Drivetrain and Brake Repair

Chain-case procedures distinguish reverse and non-reverse layouts, including shift-linkage and chain-adjuster service. Brake coverage includes hydraulic caliper and master-cylinder rebuilding, conventional mechanical brakes, and quick-adjust systems.

The Drive Belt Replacement chart and Center-To-Center/Offset specifications support belt selection and clutch alignment. The clutch assembly notes warn that mismatched timing marks can cause imbalance and damage both the clutch and crankshaft.

AWS Steering, FasTrack Suspension, and Shocks

Steering-post procedures distinguish AWS III and AWS V layouts. Rear-suspension servicing charts map models to slide-rail, front-arm, rear-arm, and idler-wheel configurations, including articulating Bearcat skid frames.

Shock repair covers valve stacks, IFP positioning, internal travel-limiting spacers, shaft seals, oil bleeding, and nitrogen charging. Remote-reservoir and clicker designs have dedicated procedures, supported by the Rebuildable Shock Piston Depth chart.

Technical Data and Specifications

The Engine Piston Travel Versus Crank Angle chart complements the timing information. Torque patterns, inspection tolerances, and chain-case fill quantities support component assembly; torque values alongside many assembly steps reduce the need to switch to separate tables.

Special-tool references include the Flywheel Puller/Spanner Wrench (p/n 0144-310) and Piston Pin Puller (p/n 0644-328).

File Format and Readability

Page breakdown: Volume I occupies 322 pages and Volume II occupies 325 pages. Volume I includes one foreword page, one master contents page, and two blank pages; these four pages are already included in the total.

Text search: Main procedure text is searchable. Many assembly-drawing and wiring-diagram labels are not searchable.

Navigation: Twelve embedded PDF bookmarks provide access to the foreword, contents, and all nine main sections.

Diagram readability: Small wire labels and connector details require zooming. Some EFI and harness diagrams have faint linework.