Positioning:
A performance-oriented trail and mountain snowmobile from Arctic Cat's popular ZR line.
Competitors:
Competed with similar displacement models from Ski-Doo (e.g., MXZ 500), Yamaha (e.g., SX500), and Polaris (e.g., RMK 500).
Features:
Lightweight chassis, powerful 500cc engine, advanced suspension for its time, 'LE' designation often indicates special edition features or graphics.
Coverage:
Complete service, maintenance, and troubleshooting for the 2002 Arctic Cat ZR 500 LE
Page Count:
Not specified, but described as 'complete'
Type:
Factory Service Repair Workshop Manual
Engine:
Detailed overhaul, inspection, and repair procedures for the 500cc engine
Fuel System:
Carburetor adjustments, cleaning, fuel pump, fuel lines
Ignition System:
CDI unit, ignition timing, spark plug specifications
Cooling System:
Radiator, hoses, coolant specifications, thermostat
Drive System:
Clutch inspection and adjustment (primary and secondary), chaincase lubrication and service
Suspension:
Front and rear suspension component inspection, adjustment, and replacement (shocks, springs, arms)
Brakes:
Hydraulic brake system service, pad replacement, fluid specifications, caliper service
Electrical System:
Wiring diagrams, component testing, lighting system, battery service
Bodywork:
Panel removal and installation, seat, handle bar, and controls service
Maintenance:
Routine maintenance checks, lubrication points, belt inspection
Troubleshooting:
Diagnostic charts and common issue resolution
Repair:
Step-by-step repair instructions for all major components
Disassembly Reassembly:
Complete disassembly and reassembly of the snowmobile
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine rebuilds and electrical diagnostics
Engine Type:
Two-stroke, liquid-cooled, parallel-twin
Engine Displacement:
494 cc
Bore X Stroke:
66.0 mm x 72.5 mm (typical for this engine family)
Power Output:
Approximately 95-105 HP (varies slightly by specific tuning)
Carburetion:
Dual Mikuni VM34 carburetors (typical)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Injection:
Yes, automatic oil injection system
Cooling Type:
Liquid-cooled
Spark Plug Replacement:
Check every 1,000 miles or annually; replace as needed based on condition (refer to manual for specific type and gap).
Clutch Inspection:
Inspect primary and secondary clutches annually or every 500 miles for belt wear, sheave condition, and roller wear.
Chaincase Lubrication:
Check and top off lubrication levels annually or every 1,000 miles. Fluid change recommended every 2,000 miles or 2 years.
Coolant Flush:
Flush and replace coolant every 2 years or 2,000 miles.
Chaincase Oil:
Arctic Cat Synthetic Chaincase Lubricant or equivalent SAE 75W-90 GL-5 gear oil.
Coolant:
Arctic Cat Performance Coolant or a 50/50 mix of ethylene glycol antifreeze and distilled water.
Clutch Wear:
Premature wear of primary and secondary clutch components (rollers, bushings, belts) can occur with aggressive riding or improper adjustment.
Heat Management:
Like many performance snowmobiles of this era, proper cooling system maintenance is crucial to prevent overheating, especially in deep snow or when ridden hard.
Carburetor Tuning:
Carburetors may require periodic cleaning and adjustment to ensure optimal performance, especially with changes in altitude or fuel quality.