Production Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Engine Code Family:
Likely Suzuki-derived twin-cylinder, liquid-cooled 2-stroke
Chassis Code Family:
ZR Platform
Target Market:
Performance-oriented trail riding and mountain riding enthusiasts. The ZR series was known for its sporty handling and aggressive styling.
Key Competitors Era:
Ski-Doo Mach Z/Formula III, Polaris Indy/XC series, Yamaha Vmax 4/SRX.
Suspension Design:
Often featured advanced suspension designs for its time, including the Arctic Wishbone Suspension (AWS) front suspension for improved steering and handling, and a capable rear suspension system.
Engine Performance:
The 600cc engine was positioned as a strong performer in the mid-to-high displacement class, offering a balance of power and agility.
Value Proposition:
Provides essential knowledge for owners and technicians to maintain, diagnose, and repair the Arctic Cat ZR 600 across a significant production span, maximizing its lifespan and performance.
Powertrain:
Engine assembly, disassembly, inspection, repair, carburetor tuning, lubrication system, cooling system, exhaust system, clutch and drive system, chaincase, rear suspension drive components.
Chassis And Suspension:
Front suspension (A-arms, shock absorbers, steering components), rear suspension (AWS - Articulated Wide Suspension, shock absorbers, springs, track drive), skis, track assembly, chassis frame, body panels, seat.
Electrical System:
Ignition system (CDI, stator, ignition coils), lighting system (headlights, taillights, brake lights), instrumentation, wiring diagrams, battery, starter system, safety interlocks.
Fuel System:
Fuel tank, fuel lines, fuel pump (if applicable), fuel filter, carburetor identification, disassembly, cleaning, adjustment, jetting specifications.
Braking System:
Hydraulic brake system, master cylinder, brake caliper, brake rotor, brake pads, brake fluid specifications.
Maintenance:
Regular servicing, lubrication points, track tension adjustment, suspension alignment checks, carburetor cleaning, clutch inspection and cleaning.
Troubleshooting:
Diagnostic charts for common issues, starting problems, power loss, unusual noises, electrical faults.
Repair And Rebuild:
Complete engine overhaul procedures, transmission/chaincase rebuild, suspension component replacement, electrical component repair, body panel repair and replacement.
Technical Adjustments:
Carburetor jetting and mixture adjustments, idle speed settings, chaincase oil level adjustments, suspension preload adjustments.
Depth:
Comprehensive factory-level detail, suitable for professional technicians and advanced DIY mechanics. Includes specifications, tolerances, torque values, diagnostic procedures, and overhaul instructions.
Configuration:
Liquid-cooled, 2-stroke, parallel-twin cylinder
Displacement:
Approximately 599cc to 600cc (exact spec may vary slightly by year/sub-model).
Bore X Stroke:
Typically around 73.2 mm x 72.0 mm (specifics may vary).
Horsepower Estimate:
Estimated 90-110 HP, depending on year and specific engine tuning.
Torque Estimate:
Not commonly quoted in HP, but strong mid-range pull.
Carburetor Type:
Dual Mikuni VM series carburetors (e.g., VM34 or VM38).
Fuel Type:
Unleaded gasoline (typically 87 octane or higher), mixed with 2-stroke oil.
Ignition Type:
CDI (Capacitor Discharge Ignition) with electronic advance.
Lubrication:
Oil injection system (APV - Arctic Power Valve system often featured, requiring premix or oil injection) and pre-mix oil for fuel.
Overall Length:
Varies by year, typically 100-110 inches (approx. 254-279 cm).
Overall Width:
Varies by year, typically 46-48 inches (approx. 117-122 cm).
Dry Weight:
Typically in the range of 450-500 lbs (approx. 204-227 kg).
Fuel Capacity:
Around 10-11 gallons (approx. 38-42 liters).
Crash Test Ratings:
N/A (Snowmobiles are not subject to the same crash testing standards as automobiles).
Braking System:
Hydraulic disc brake system, typically on the driveshaft or track.
Kill Switch:
Standard handlebar-mounted emergency kill switch with a tether cord.
Lighting:
Headlights, taillight, and brake light for visibility.
Windshield:
Standard windshield to protect the rider from wind and debris.
Instrument Cluster:
Analog gauges for speedometer, tachometer, and engine temperature. Indicator lights for oil, low beam, high beam, and neutral.
Braking Assistance:
No electronic ABS or traction control. Relies on mechanical brake system.
Lighting System:
Halogen headlight, LED taillight/brake light.
Initial Break In:
Specific break-in procedure for new engines, typically involving varying throttle and speed for the first few hours of operation.
Oil Change Chaincase:
Every 2,000-3,000 miles or annually, whichever comes first.
Spark Plug Replacement:
As per manual recommendations, typically every 1,000-2,000 miles or based on inspection.
Carburetor Cleaning:
Annually or as needed, especially before storage.
Clutch Maintenance:
Inspect and clean primary and secondary clutches annually for optimal performance.
Engine Oil Type:
Arctic Cat Premium 2-Stroke Oil, or equivalent high-quality JASO FD certified 2-stroke oil for oil injection system. For premix, use a quality 2-stroke oil suitable for the engine's operating conditions.
Chaincase Oil Type:
Arctic Cat Synthetic Chaincase Lubricant or equivalent SAE 75W/90 synthetic gear oil.
Coolant Type:
Permanent type antifreeze/coolant, typically a 50/50 mix of ethylene glycol and distilled water. Consult manual for specific Arctic Cat coolant. Avoid silicate-based coolants.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch components (weights, springs, buttons), carbides on skis, track lugs, drive sprockets, shock absorbers, and suspension bushings.
Engine Considerations:
Early 2-stroke engines can be sensitive to proper jetting and oil mixture, leading to piston or cylinder damage if not maintained. Power valves (if equipped) require cleaning and inspection.
Electrical Issues:
Wiring harness fatigue or corrosion can lead to intermittent electrical problems. CDI unit or stator failure can cause ignition issues.
Carburetor Jetting:
Manual provides detailed main jet, pilot jet, needle, and air screw specifications for various altitudes and temperatures.
Ignition Timing:
Specific ignition timing specifications and procedures for checking and adjusting via CDI unit.
Suspension Alignment:
Specifications for ski-to-ski alignment and caster/camber adjustments.
Arctic Cat Legacy:
Arctic Cat has a long history in snowmobile manufacturing, dating back to the early 1960s, known for innovation and performance.
Zr Series Introduction:
The ZR series represented a significant step forward in performance and handling for Arctic Cat, introduced in the late 1980s/early 1990s.
Powertrain Development:
The 600cc twin-cylinder engine became a popular choice, refined over the years for increased power and reliability.
Manufacturing Location:
Primarily manufactured in Thief River Falls, Minnesota, USA.
