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Arctic Cat Snowmobile 2002 Service Repair Manual

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156.415 MB PDF File

Complete Service Repair Manual
Arctic Cat Snowmobile 2002

This Manual is specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep you vehicle working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. The high level of detail, along with hundreds of illustrations and details guide the reader through each service and repair procedure.
This is the same manual used by dealer technicians to service, repair and mantain your Arctic Cat Snowmobile 2002.

Models covered:
Bearcat Widetrack
Mountain Cat 500
Mountain Cat 570
Mountain Cat 600 EFI/600 EFI LE
Mountain Cat 800/800 LE
Mountain Cat 800 EFI/800 EFI LE
Mountain Cat 1000
Pantera 550
Pantera 600 EFI
Pantera 800 EFI
Panther 440
Panther 570 esr/570 r
Thundercat 1000
Z 370/370 es
Z 440/440 es
Z 570/570 esr Z 570 SS
ZL 500
ZL 550/550 esr
ZL 600 EFI/600 EFI esr ZL 600 EFI SS
ZL 800 EFI esr ZL 800 EFI SS
ZR 120
ZR 500 ZR 500/500 LE/500 CC
ZR 600 ZR 600 EFI/600 EFI CC
ZR 800/800 CC ZR 800 EFI/800 EFI CC
ZRT 600

Index of Contents:
1 - General Information
Snowmobile Identification
Recommended Gasoline and Oil
Break-In Procedure
Genuine Parts
High Altitude Operation
Drive Chain Lubrication (120 cc)
Preparation For Storage
Preparation After Storage
After Break-In Checkup Checklist
Torque Conversions
Tightening Torque (General Bolts)
Fraction/Decimal Conversion Chart
Drill Bit Sizes (Number) Chart
MM/In. Conversion Chart
Servicing Symbols
2 - Engine
Engine
Removing Engine (Table of Contents)
Disassembling Engine (Table of Contents)
Servicing Components (120 cc)
Cleaning and Inspecting Engine
Measuring Critical Components
2002 Arctic Cat Engine Specifications
Assembling Engine (Table of Contents)
Assembly Schematics (Table of Contents)
Installing Engine (Table of Contents)
Troubleshooting Engine (120 cc)
Troubleshooting Engine (Carbureted Models)
Troubleshooting Engine (EFI Models)
Troubleshooting Engine
3 - Axial Fan/Belt (370/440 cc)
Repairing Water Pump (Twin)
Repairing Water Pump (600 cc Triple)
Repairing Water Pump (1000 cc)
Pressure Testing Engine
Liquid Cooling System
Cooling System Schematics
Recoil Starter (120 cc Model)
Recoil Starter
Arctic Power Valve (APV) System
4 - Fuel Systems
Fuel System (Carbureted)
Fuel System (Batteryless EFI)
Fuel System (Related Items)
5 - Electrical Systems
2002 Electrical Specifications Chart
Resistance Tests Chart
Electrical Specifications (Individual)
Transistorized Ignition System (120 cc Model)
Testing Electrical Components3
Troubleshooting/Testing Ignition System
120 cc Model
EFI Models
Fan Cooled Models
Twin L/C & Triple Models
Digital 3-D Ignition
(500/600/800/1000 cc Models)
Testing Main Wiring Harness (120 cc Model)
Testing Electrical Resistances
120 cc Model
EFI Models
370 cc Models/440 cc Panther Model
500/600 cc Twin Carburetor Models
440 cc Z Models/550 cc Models
600 cc Triple Model
800 cc Carbureted Models
570/1000 cc Models
Peak Voltage Tests (Fan Cooled Models)
Peak Voltage Tests (Carbureted APV Models)
Peak Voltage Tests (EFI Models/550/1000 cc Models)
Testing Low-Oil Light Sensor
Testing High Temperature Sensor
Testing High Temperature Warning Light
Testing Fuel Gauge
Testing Fuel Gauge Sender
Testing Electric Fuel Pump
Electric Start Components
Solenoid
Charging Diode
Fuse
Ignition Switch - Electric Start Function
Starter Motor
Troubleshooting Electric Start
Wire Color Code and Function Description
Ignition Timing
2002 Ignition Timing Specifications
2002 Wiring Diagram Index (Ignition)
2002 Wiring Diagrams
6 - Chassis electrical Systems
Brakelight Switch (Hydraulic System)
Brakelight Switch (Mechanical System)
Headlight Dimmer Switch
Testing Handlebar Warmer Elements(ON/OFF Function)
Testing Thumb Warmer Element(ON/OFF Function)
Testing Handlebar Warmer Elements(HI/OFF/LO Function)
Testing Thumb Warmer Element(HI/OFF/LO Function)
Testing Handlebar Warmer Switch(ON/OFF Function)
Testing Handlebar Warmer Switch(HI/OFF/LO Function)
Testing Thumb Warmer Switch(OFF/ON Function)
Testing Thumb Warmer Switch(HI/OFF/LO Function)
Testing Passenger Handwarmer Switch
Testing Passenger Handwarmer Elements
Wire Color Code and Function Description
2002 Wiring Diagrams (Main and Hood)
7 - Steering and Body
Steering
Steering Post (120
Steering Post (AWS III)
Steering Post (AWS V)
Ski
Ski (120 cc)
Ski Wear Bar
Drag Link
Tie Rods (120 cc)
Front Tie, Rods
Spindle
Steering Tie Rod
Ski Alignment
Front Suspension A-Arms (120 cc)
Front Suspension Arms
Front Suspension (Ski) Shock Absorber
Sway Bar
Console (EFI Models)
Console (Carbureted Model - Style A)
Console (Carbureted Models - Style B)
Belly Pan
Seat/Cushion/Taillight Housing (120 cc)
Taillight Housing
Windshield
Backrest/Rack/Taillight Assembly
Tunnel/Rear Bumper/Snowflap
Headlight Assembly (120 cc)
Headlight Assembly (1 Bulb Halogen
Adjusting Headlight Aim (1 Bulb Halogen)
Headlight Assembly (3 Bulb Halogen)
Adjusting Headlight Aim (3 Bulb Halogen)
Torque Specifications
Torque Specifications (General Bolts)
8 - Drive Train and brake system
Drive Train and Brake Systems
Drive Chain and Sprockets (120 cc)
Drive Belt
Drive Clutch
Driven Pulley
Drive Clutch/Driven Pulley
Drive Train Schematics (w/Reverse)
Drive Train Schematics (w/o Reverse)
Drive Train/Brake Disc (w/Reverse)
Drive Train/Brake Disc (w/o Reverse)
Chain Adjuster
Brake System (Hydraulic)
Brake Lever/Master Cylinder Assembly (Hydraulic System)
Brake System (Mechanical/Quick-Adjust)
Brake Control (Mechanical/Quick-Adjust)
2002 Drive System Specifications (Production)
Chain Case Performance Specifications
With Tension Pad Tightener System
Chain Case Performance Specifications
With Roller Tightener System
Drive System Components
Arctic Cat Cam Arms
Comet Cam Arms
Comet-To-Arctic Cat Cam Arm Conversion Chart
Chains & Sprockets
Arctic Cat Drive Belt Dimension Chart
Arctic Cat Drive Belt Replacement Chart
Center-To-Center/Offset Specifications
Torque Specifications
Troubleshooting Drive Clutch/Driven Pulley
Troubleshooting Drive Belt
Troubleshooting Hydraulic Brake System
9 - Track / Rear Suspension
Understanding the Suspension
Suspension Setup Basics
2002 Suspension Mounting Location Chart
Chassis and Skid Frame
Mounting Locations (2002)
Servicing Chart
Slide Rail Schematics 3
Front Arm Schematics
Rear Arm Schematics
Idler Wheels Schematics
Articulating Skid Frame Schematic
Repair Procedure 1
Repair Procedure 2
Repair Procedure 3
Repair Procedure 4
Drive Sprocket Location
Drive Track Usage Chart
Drive Track Lug Patterns
Idler Wheel Selection Chart
Torque Specifications
Rebuildable Shock Absorber Usage Guide
Rebuildable Shock Accessory Part Numbers
Shock Absorber Usage Guide
Rear Spring Selection Chart
Front Suspension Ski Springs
Front Suspension Sway Bar
Rear Suspension (Front Arm Springs)
Standard Shock & Spring Chart - 2002 Models
Optional Rear Arm Spring Chart - 2002 Models
Rebuildable Shock Piston Depth Chart
Rebuildable Shock Tools Required
Rebuildable Shock Rebuild Kits
2002 Valve Stacks
Servicing IFP Style Shocks
Servicing Front Arm Quick-Adjust Shock
Installing Internal Travel Limiting Spacers
Servicing Rebuildable Shocks & Remote
Reservoir w/Clicker
Bearing Cap and Shaft Seal
Shaft Eyelet
Ski Shocks Bottom-Out Bumper
Pressurizing Rebuildable Shocks
Troubleshooting Track


Language: ENG
File Format: PDF
Requirements: Adobe PDF Reader
Specifications: High quality - Fully Bookmarked - Printable
Compatible: All Windows and Mac Computers

All systems, maintenance and repairs are covered.
Hundreds of photos & Wiring diagrams showing complete procedures of disassembly and reassembly.


(ID 6480010)

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