Manual Type:
Factory Service Repair Manual
Printability:
Fully Printable (individual pages or entire manual)
Page Count:
Hundreds of pages (specific count not provided, but described as comprehensive)
Manual Source:
Actual Genuine Repair Service Factory Manuals (not third-party)
Systems Covered:
• General Information
• Engine
• Engine-Related Items
• Fuel Systems
• Engine Electrical Systems
• Chassis Electrical Systems
• Steering and Body
• Drive Train System
• Brake Systems
• Track/Rear Suspension
Engine Related Items:
Likely includes lubrication system, cooling system, exhaust system, and engine mounts.
Fuel Systems:
Detailed coverage of EFI components, fuel pump, injectors, fuel filter, and fuel tank.
Engine Electrical Systems:
Ignition system, charging system, starter motor, lighting coils, sensors, and ECU.
Chassis Electrical Systems:
Wiring harnesses, switches, controls, and accessories.
Steering And Body:
Handlebar controls, steering linkages, front suspension, body panels, seat, and windshield.
Drive Train System:
Clutches (primary and secondary), drive belt, chaincase, gears, and track drive components.
Brake Systems:
Brake caliper, master cylinder, brake lines, brake fluid, and parking brake mechanism.
Track Rear Suspension:
Rear suspension system (e.g., Arctic Cat's FasTrack suspension), shock absorbers, torsion springs, idler wheels, and track assembly.
Procedures Included:
• Maintenance
• Diagnosis of engine fault symptoms
• Repair evaluation and approach
• Component testing (including specialized techniques)
• Wiring diagram tracing and verification
• Engine management system analysis
• Troubleshooting guides
• Rebuilding procedures
• Restoration guidance
• Common fixes and preventative tips
Common Fixes:
Provides insights into frequently encountered issues and their remedies, enabling informed conversations with mechanics.
Mechanic Evaluation:
Empowers owners to assess the competence of service technicians and ask pertinent questions.
Wiring Diagrams:
Detailed wiring diagrams for tracing and verifying electrical circuits.
Technical Depth:
Comprehensive, covering fundamentals to advanced diagnostics and rebuilds, mirroring factory technician knowledge.
Repair Procedures:
All diagnostic and repair procedures are covered in great detail, enabling complete rebuilds and restorations.
Engine Type:
Liquid-Cooled, Two-Stroke
Engine Displacement:
597cc (approximate, based on model designation)
Fuel System:
Electronic Fuel Injection (EFI)
Induction Type:
Electronic Fuel Injection (EFI)
Estimated Horsepower:
Approximately 115-120 HP (typical for this class and era)
Engine Cooling:
Liquid-Cooled
Torque Output:
Refer to manual for specific torque figures (estimated range for this displacement and configuration would be around 70-80 ft-lbs)
Engine Management System:
EFI system with ECU control for fuel delivery and ignition timing, optimizing performance and emissions.
Instrumentation:
Digital/Analog gauge cluster including speedometer, tachometer, engine temperature, and fuel level.
Spark Plug Replacement:
Refer to manual for specific interval (typically 1,500-3,000 miles or annually)
Drive Belt Inspection:
Regular inspection recommended (refer to manual for mileage intervals)
Carburetor Cleaning:
N/A (EFI model, but similar EFI system cleaning/inspection intervals apply)
Clutch Maintenance:
Refer to manual for specific mileage intervals for inspection and service of primary and driven clutches.
Engine Oil Type:
2-Stroke Snowmobile Oil (specific Arctic Cat recommendation in manual)
Coolant Type:
Ethylene Glycol based Antifreeze/Coolant (50/50 mix recommended)
Chaincase Oil Type:
Refer to manual for specific lubricant (likely a dedicated chaincase oil)
Brake Fluid Type:
DOT 4 Brake Fluid (standard for hydraulic disc brakes)
Known Issues:
• Carburetor/EFI system cleaning and tuning
• Drive clutch and driven clutch maintenance (belt wear, alignment)
• Suspension component wear (bushings, shocks)
• Track and hyfax wear
• Starter system reliability
Brand Heritage:
Arctic Cat has a long-standing history in snowmobile manufacturing, known for performance and innovation since the early 1960s.
Model Evolution:
The ZL series represented Arctic Cat's performance-oriented trail sleds, often featuring powerful engines and comfortable ergonomics. The ZL 600 EFI was a key model in this line, benefiting from the advancements of fuel injection technology for improved performance and reliability.