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Arctic Cat ZL 600 2000 Service Repair Workshop Manual

$16.99
$16.99
The Arctic Cat ZL 600, produced in 2000, is a performance trail snowmobile known for its strong performance on groomed trails, comfortable ride, and reliable 597cc Rotax engine. This model...
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Type: Snowmobile
Vendor:
Arctic Cat
Sku: 104092
Tags: 2000 Arctic Cat ATV Misc Powersports Snowmobile ZL 600
Arctic Cat ZL 600 2000 Service Repair Workshop Manual
The Arctic Cat ZL 600, produced in 2000, is a performance trail snowmobile known for its strong performance on groomed trails, comfortable ride, and reliable 597cc Rotax engine. This model was a popular choice among enthusiasts, offering a balance of comfort, handling, and power, and was considered a strong competitor in its segment. Its engineering quality and reliability contributed to its positive reputation within the snowmobiling community. This comprehensive service repair workshop manual provides full service and repair instructions for the Arctic Cat ZL 600, targeting mechanics worldwide. It covers essential areas including detailed engine mechanical and fuel system procedures, clutch and drive system maintenance, suspension and steering system repair, and electrical system diagnostics. The manual also includes troubleshooting guides, preventive maintenance schedules, and technical specifications such as torque values and clearances, ensuring owners and technicians can effectively maintain and repair the vehicle.
🏷️ Basic Information
Identification
Make:
Arctic Cat
Model:
ZL 600
Year:
2000
Product Type:
Service Repair Workshop Manual
👋 Introduction
Market Position
Segment:
Performance Trail Snowmobile
Competitive Analysis
Competitors 2000:
Ski-Doo MXZ 600, Yamaha Vmax SX 600, Polaris XC 600
Key Features
Vehicle Features:
Known for its strong performance on groomed trails, comfortable ride, and reliable Rotax engine.
📋 Manual Details
Coverage Areas
General Coverage:
Full service and repair instruction
Target Audience:
Mechanics worldwide
Page Count
Estimated Page Count:
400+
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul, inspection, and repair of the 600cc Rotax engine (e.g., cylinders, pistons, crankshaft, connecting rods, lubrication system).
Engine Fuel System:
Carburetor tuning, cleaning, and rebuilding (likely Mikuni VM series), fuel pump operation, fuel line maintenance.
Engine Ignition System:
CDI unit testing, stator and lighting coil testing, spark plug specifications, ignition timing adjustment (if applicable).
Engine Cooling System:
Radiator maintenance, coolant specifications, water pump inspection and repair, thermostat operation.
Drive System Clutch:
Primary and secondary clutch (Drive and Driven clutches) maintenance, inspection, spring and weight replacement, belt inspection and replacement procedures.
Drive System Chaincase:
Chaincase oil type and level, chain inspection and tension adjustment, gear inspection, bearing checks.
Suspension Front:
IFS (Independent Front Suspension) components, shock absorber inspection and service, A-arm bushings, spindle assembly, ski alignment and tuning.
Suspension Rear:
Rear suspension (e.g., Arctic Cat's FasTrack™) inspection, shock absorber service, idler wheel maintenance, track inspection and adjustment, suspension arm alignment.
Steering System:
Handlebar and steering post assembly, tie rod end inspection and adjustment, spindle alignment, shock dampener (if applicable).
Braking System:
Hydraulic disc brake caliper inspection, pad replacement, fluid type and bleeding procedures, brake lever and cable adjustment.
Electrical System:
Wiring diagrams, headlight, taillight, and instrument cluster troubleshooting, battery maintenance, starter motor operation, kill switch functionality.
Bodywork And Chassis:
Hood removal and installation, seat removal, plastic panel maintenance, chassis inspection for damage, decal application.
Procedures Included
Preventive Maintenance:
Scheduled maintenance intervals, lubrication points, belt tension checks, track tension adjustments.
Troubleshooting Guides:
Diagnostic charts for common starting, running, and electrical issues.
Engine Rebuild:
Complete step-by-step instructions for engine disassembly, inspection of wear components, reassembly, and break-in procedures.
Clutch Service:
Detailed procedures for clutch removal, cleaning, inspection of weights, helix, and spring, and reassembly.
Suspension Repair:
Replacement of A-arm bushings, shock absorber service, ski spindle repair, and front-end alignment.
Brake System Repair:
Brake caliper overhaul, brake pad replacement, brake fluid bleeding, and cable adjustment.
Electrical Diagnostics:
Troubleshooting of lighting circuits, ignition system faults, and starter system issues using specific test procedures.
Track And Skis:
Track tension adjustment, alignment, and inspection; ski rubber condition and alignment.
Technical Depth
Depth:
Comprehensive; covers everything from basic maintenance to full engine and component overhauls.
Torque Specifications:
Includes detailed torque values for critical fasteners across all systems.
Clearances And Tolerances:
Provides essential specifications for engine component clearances (piston to cylinder wall, ring end gap, bearing clearances).
Wiring Diagrams:
Detailed electrical schematics for the entire snowmobile.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF allowing for quick text retrieval of information.
Print Quality
Quality:
High-resolution scans ensuring clarity of diagrams, illustrations, and text.
Binding Type
Binding:
Not applicable (digital format).
Paper Type
Paper:
Not applicable (digital format).
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-Stroke, Liquid-Cooled, Parallel-Twin
Displacement:
597 cc
Bore X Stroke:
73.5 mm x 71.0 mm (typical for Rotax 600 series)
Carburetion:
Dual Mikuni VM34 or VM36 carburetors
Ignition:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid-Cooled
Performance
Horsepower Estimate:
Approx. 100-110 HP (varied slightly by tune)
Torque Estimate:
Not explicitly stated, but strong mid-range power delivery
Fuel System
Fuel Type:
Unleaded Gasoline (87-91 Octane)
Oil Mixture:
Premix or Oil Injection (depending on specific ZL 600 variant, typically oil injection for this era)
🔧 Transmission
Standard
Type:
CVT (Continuously Variable Transmission) - Arctic Cat's ACT™ Drive System
Drive Clutch:
Arctic Cat's ACT™ Drive Clutch (Adjustable)
Driven Clutch:
Arctic Cat's ACT™ Driven Clutch
Features
Gear Ratios:
Variable (CVT) - optimized for performance and efficiency
Chaincase Fluid:
Arctic Cat Chaincase Lubricant (GL-4 Gear Oil 75W-90 or equivalent)
📐 Dimensions
Exterior
Length Estimate:
Approx. 105-110 inches (267-279 cm)
Width Estimate:
Approx. 47-48 inches (119-122 cm)
Weights
Dry Weight Estimate:
Approx. 450-470 lbs (204-213 kg)
Fuel Capacity:
Approx. 10.5 gallons (39.7 Liters)
🛡️ Safety Features
Ratings
Crash Test Data:
Not applicable to snowmobiles in the same way as automobiles.
Active Features
Braking System:
Hydraulic Disc Brake
Engine Kill Switch:
Standard handlebar-mounted kill switch.
Passive Features
Body Structure:
Steel chassis and reinforced polymer body panels for rider protection.
Lighting:
Halogen headlight, taillight, and brake light for visibility.
💡 Technology Features
Infotainment
Dashboard Features:
Speedometer, Tachometer, Odometer, Fuel Gauge, Coolant Temperature Gauge, Neutral Indicator, High Beam Indicator, Oil Warning Light.
Driver Assistance
Braking Control:
Hydraulic disc brake provides primary stopping power.
Connectivity
Not Applicable:
No electronic connectivity features like Bluetooth or USB ports.
🔧 Maintenance
Service Intervals
Initial Break In:
Recommended engine break-in procedures detailed in the manual (typically first 500 miles or 10 hours).
Oil Change Chaincase:
Every 1,000 miles or annually.
Clutch Inspection:
Annually or every 500 miles.
Spark Plug Replacement:
Every 1,000-1,500 miles (refer to manual for specific type and gap).
Fluid Specifications
Engine Oil Injection:
API-TC Certified 2-stroke snowmobile oil (e.g., Arctic Cat APV Synthetic)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Known Issues
Common Wear Items:
Drive belt, clutch weights/rollers, suspension bushings, carbides on skis, track lugs.
Engine Specific Considerations:
Proper oil mix and regular carburetor cleaning are critical for Rotax twin-cylinder engines of this era.
📚 Vehicle History
Brand Heritage
Arctic Cat Legacy:
Arctic Cat has a long history in snowmobiling, dating back to the early 1960s, known for innovation and performance.
Model Evolution
Zl Series Positioning:
The ZL series was a popular line of trail-oriented snowmobiles, offering a balance of comfort, handling, and power.
Zl 600 Evolution:
The 2000 model benefited from continuous improvements in the Rotax engine technology and chassis design.
Production
Manufacturing Location:
Typically manufactured by Arctic Cat in Thief River Falls, Minnesota, USA.
🏆 Awards & Recognition
Recognitions
Industry Reputation:
The ZL 600 was generally well-regarded for its trail performance and comfort, making it a popular choice among enthusiasts.
Ratings
Customer Reviews:
Likely received positive reviews for its powerful engine and stable handling.
Certifications
Not Applicable:
No specific safety or performance certifications typically listed for snowmobiles.
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