Market Segment:
Performance Trail/Mountain Snowmobile
Competitors 2000:
Ski-Doo MXZ series, Yamaha Vmax series, Polaris RMK/XCR series.
Efi Advantage:
Electronic Fuel Injection provides improved throttle response, easier starting, better fuel economy, and altitude compensation compared to carbureted models.
Performance Focus:
The ZR 600 EFI was a popular model for its balance of power, handling, and reliability for aggressive trail riding and moderate mountain use.
Systems Covered:
Engine mechanical, fuel system (EFI), ignition system, exhaust, cooling system, lubrication, drivetrain (clutch, chaincase), suspension (front and rear), steering, brakes, electrical system (lighting, accessories), body panels, skis, track.
Page Count:
Hundreds of pages (exact count not specified in product data)
Manual Type:
Factory Service Repair Manual
Engine Systems:
Complete engine disassembly, assembly, inspection, diagnosis, and repair for the 599cc liquid-cooled twin-cylinder engine.
Fuel System:
Detailed procedures for the Electronic Fuel Injection (EFI) system, including fuel pump, injectors, sensors (TPS, MAP, IAT, ECT), ECU, and troubleshooting.
Drivetrain Systems:
Diagnosis and repair of the Arctic Cat/Team primary and secondary clutches, chaincase, gears, bearings, and drive chain.
Suspension Systems:
Front A-arm suspension geometry, shock absorber servicing, spindle, tie rod, and ski alignment procedures. Rear suspension (likely Arctic Cat's FasTrack system) overhaul, shock servicing, and alignment.
Electrical Systems:
Wiring diagrams, component testing, troubleshooting for lighting, ignition, starter, charging system, and EFI components.
Routine Maintenance:
Oil changes, spark plug replacement, belt inspection/replacement, chain tensioning, general lubrication points.
Diagnostic Procedures:
Step-by-step troubleshooting guides for common performance issues, starting problems, and EFI fault codes.
Repair Procedures:
Complete instructions for component removal, installation, rebuilding, and adjustment.
Specification Data:
Torque specifications, clearances, gap settings, fluid capacities, and electrical resistance values.
Depth:
Comprehensive, covering everything from basic adjustments to full engine rebuilds and complex EFI diagnostics.
Engine Type:
2-Stroke, Liquid-Cooled, Twin-Cylinder
Displacement:
599 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 73.0 mm (Typical for this era Suzuki engine)
Cooling System:
Liquid-Cooled
Horsepower Estimated:
Approximately 105-115 HP (Exact figures vary by specific tuning and source, but within this range for the 600cc EFI).
Torque Estimated:
Not explicitly provided in product data, but strong mid-range torque is characteristic of this engine for its class.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Type:
CVT (Continuously Variable Transmission) with Arctic Cat/Team clutches
Primary Clutch:
Arctic Cat ACT Drive System (Adjustable Clutch Technology)
Secondary Clutch:
Team Tied Secondary Clutch
Gear Reduction:
Internal chaincase with specific gear ratios (detailed in manual)
Length Overall:
Specific dimensions not provided in product data, but typically around 105-110 inches for this class of snowmobile.
Width Overall:
Specific dimensions not provided in product data, but typically around 46-48 inches.
Dry Weight:
Approximately 450-475 lbs (Dry weight, not including fluids or rider)
Crash Test Ratings:
Snowmobiles are not typically rated by organizations like NHTSA. Safety is addressed through design features.
Braking System:
Hydraulic disc brake, typically with a lightweight rotor and caliper.
Lighting:
Halogen headlights, taillight, and brake light for visibility.
Dashboard Features:
Analog speedometer and tachometer, fuel gauge, coolant temperature gauge, and indicator lights for various systems. May include basic odometer/trip meter.
Efi System Functionality:
The EFI system acts as a primitive form of driver assistance by optimizing engine performance across varying conditions, improving reliability over carbureted systems.
Diagnostic Port:
While not modern OBD-II, the EFI system would have a diagnostic port or method for connecting specialized tools to read fault codes and sensor data, detailed in the manual.
Oil Change Interval:
Refer to manual; typically every 50-75 hours or annually. Use of correct Arctic Cat injection oil is critical.
Spark Plug Replacement:
Refer to manual; typically at the start of each season or every 1,000-1,500 miles. Recommended plugs: NGK BR9ES or similar.
Clutch Inspection Interval:
Regular inspection for wear, belt condition, and proper sheave condition is recommended every 50-100 hours.
Engine Oil Type:
Arctic Cat Premium 2-Stroke Injector Oil (or equivalent API TC or JASO FD certified synthetic 2-stroke oil).
Chaincase Oil Type:
Arctic Cat Synthetic Chaincase Lubricant (or SAE 80W-90 hypoid gear oil).
Coolant Type:
Ethylene Glycol based antifreeze/coolant (50/50 mix with distilled water), rated for extreme cold temperatures.
Efi Sensor Failures:
As with many EFI systems of this era, sensors like the Throttle Position Sensor (TPS) or Manifold Absolute Pressure (MAP) sensor can fail, leading to performance issues. The manual will detail diagnosis.
Clutch Belt Wear:
Regular inspection and replacement of the drive belt is crucial to prevent catastrophic failure. Worn clutch components can also lead to poor performance.
Exhaust Flange Leaks:
Some early EFI models could experience exhaust flange leaks due to vibration or improper tightening. The manual will cover proper torque and sealing.
Arctic Cat Legacy:
Arctic Cat has a long history in snowmobile manufacturing, dating back to the 1960s, known for performance and innovation.
Zr Series Development:
The ZR series was Arctic Cat's flagship performance line, evolving through various engine displacements and chassis designs from the mid-1990s onwards, focusing on rider ergonomics and suspension.
Production Years:
The ZR 600 EFI was produced in the late 1990s and early 2000s, with significant updates and variations throughout that period.
