🏷️ Basic Information

Make:

Arctic Cat

Model:

ZR Series Snowmobiles

Years Covered:

1999, 2000

Specific Models Covered:

ZR 600, ZR 600 EFI, ZR 600 EFI LE, ZR 700, ZR 700 LE, ZRT 600, ZRT 800

Internal Product Code:

AC-ZR-9900-WSM

👋 Introduction

Positioning:

High-performance trail and mountain snowmobiles targeted at recreational riders and enthusiasts. Known for their power and handling.

Competitors:

Competed directly with Yamaha Vmax series, Ski-Doo Mach Z/Formula III, and Polaris XCR/RMK models of the same era.

Performance Focus:

Emphasis on powerful twin-cylinder engines and agile chassis design for dynamic trail riding.

Efi Technology:

Introduction of Electronic Fuel Injection (EFI) on select models for improved throttle response, fuel efficiency, and altitude compensation.

📋 Manual Details

General Coverage:

Complete Service and Repair Procedures A-Z

Estimated Page Count:

Approx. 800-1200 pages (typical for comprehensive snowmobile workshop manuals of this era)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Engine:

Engine assembly, disassembly, tuning, cooling system, lubrication system, fuel system (EFI and carbureted variants), ignition system, exhaust system, starting system.

Drivetrain:

Drive clutch, driven clutch (primary and secondary), chaincase, gears, drive shaft, track system, suspension (front and rear).

Electrical:

Wiring diagrams, lighting system, ignition switch, starter motor, alternator/stator, battery, CDI unit, sensors, gauges, control modules.

Chassis And Body:

Frame inspection, handlebars, steering system, seat, body panels, skis, snow flap, lubrication points.

Brakes:

Brake system components, hydraulic lines, master cylinder, caliper, brake disc, brake lever, parking brake.

Fuel And Emissions:

Fuel tank, fuel lines, fuel pump (if applicable), fuel filters, EFI system components (injectors, throttle body, sensors), emissions control systems (if applicable).

Maintenance:

Regular inspections, lubrication, fluid checks and changes, filter replacements, belt inspection and replacement, spark plug replacement, battery maintenance.

Repair:

Engine rebuilds, clutch adjustments and replacements, suspension component repair, brake system overhaul, electrical component troubleshooting and replacement, steering system repair.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, electrical fault finding.

Technical Adjustments:

Carburetor tuning (for non-EFI models), EFI system calibration (basic adjustments), ignition timing checks, chaincase tension adjustment.

Depth:

Comprehensive, covering from basic routine maintenance to complete engine and drivetrain overhauls. Includes detailed exploded diagrams and torque specifications.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High Resolution, suitable for printing individual pages or entire chapters.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Software:

Adobe Reader (or compatible PDF viewer)

⚙️ Engine Specifications

Engine Type:

2-stroke, Liquid-Cooled Twin Cylinder

Displacement 600:

597cc (approximately)

Displacement 700:

698cc (approximately)

Displacement 800:

794cc (approximately)

Horsepower 600:

Approx. 115-125 HP (depending on specific model and tuning)

Horsepower 700:

Approx. 125-135 HP (depending on specific model and tuning)

Horsepower 800:

Approx. 140-150 HP (depending on specific model and tuning)

Fuel System 600 Efi:

Electronic Fuel Injection (EFI) with throttle body injection

Fuel System Carbureted:

Mikuni VM carburetors (e.g., 38mm or 40mm)

Fuel Type:

Unleaded Gasoline (87-91 Octane Recommended)

Oil Injection:

Automatic Oil Injection System (oil reservoir separate from fuel)

🔧 Transmission

Clutch System:

Arctic Cat Variable Ratio Drive System (CVT - Continuously Variable Transmission) with primary (drive) and secondary (driven) clutches.

Gearing:

Chaincase with multiple gear ratios for different applications (trail, mountain). Specific ratios would be detailed in the manual.

Clutch Calibration:

Manual provides detailed information on clutch calibration, weights, springs, and helix for performance tuning based on riding conditions.

📐 Dimensions

Track Length:

Typically 121 inches (3073 mm) or 136 inches (3454 mm) for trail models, longer for mountain variants. Specific dimensions would vary by sub-model.

Track Width:

Typically 15 inches (381 mm)

Dry Weight:

Approx. 450-500 lbs (204-227 kg) depending on model and configuration.

🛡️ Safety Features

Crash Test Data:

N/A (Snowmobiles are not subject to automotive crash testing standards)

Braking System:

Hydraulic Disc Brake, located at the drive shaft or jackshaft.

Rollover Protection:

N/A (Snowmobiles do not typically feature integrated rollover protection like enclosed vehicles).

Warning Systems:

Indicator lights for engine temperature, low oil, and other critical systems as detailed in the manual.

💡 Technology Features

Gauge Cluster:

Digital/analog gauge cluster providing speed, RPM, fuel level, coolant temperature, and warning lights.

Efi Management:

Electronic Fuel Injection on specific models provides automatic engine management for optimal performance and emissions.

Diagnostic Ports:

Manual will detail any diagnostic access points or procedures for EFI systems.

🔧 Maintenance

Oil Change Interval:

Intervals depend on usage; manual will specify based on mileage or operating hours. Typically, oil filter replacement during major service.

Clutch Maintenance:

Regular cleaning and inspection of clutches, belt condition check (replace if frayed or worn).

Spark Plug Replacement:

Recommended based on mileage or if fouled. Manual will provide specific plug type and gap.

Chaincase Oil:

Arctic Cat recommends specific chaincase lubricant (e.g., Arctic Cat Syn-3 or equivalent synthetic gear oil).

Coolant:

Permanent type antifreeze/coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity.

2 Stroke Oil:

High-quality synthetic 2-stroke snowmobile oil specifically designed for oil injection systems. Manual will recommend Arctic Cat branded oil or equivalent.

Clutch Wear:

Common to all CVT systems, clutches can require adjustment or replacement due to wear on belt, buttons, or weights.

Suspension Bushings:

Wear on suspension bushings can lead to play and affect handling; manual will cover inspection and replacement.

Efi Sensor Issues:

On EFI models, sensors like TPS or MAP can sometimes require cleaning or replacement if performance is affected.

📚 Vehicle History

Arctic Cat Legacy:

Arctic Cat has a long-standing history in snowmobile manufacturing, known for innovation and performance-oriented designs since the early 1960s.

Zr Series Development:

The ZR series represented Arctic Cat's push towards lighter, more agile chassis designs and powerful engine options, building on earlier models like the EXT and Panther.

Manufacturing Location:

Primarily manufactured in Thief River Falls, Minnesota, USA.

🏆 Awards & Recognition

Industry Awards:

Arctic Cat models from this era often received praise for their performance and chassis dynamics from snowmobile enthusiast publications.

Performance Reviews:

Consistently reviewed as powerful and capable trail performers, particularly the ZRT models.