Why the
90 degree front bend came about

The finest wear rods and... we can prove it!

NEW FOR 1994 – Arctic Cat Plastic Skis

Engineered, tested, and perfected exclusively by Arctic. These high impact plastic skis delivered excellent performance. Each ski is a full 6 pounds lighter than traditional steel skis. (Not accurate, each plastic ski is only 3 ¼ lb lighter, not 6 lbs.) That adds up to performance and response. Plastic Skis kit - 0638-416 - $299.95.

“Finding A Cure”
Tips, tricks and complete rebuilds for the 95’s.
Compiled by Pat Bourgeois
Make it Fit (He bent over backwards not to say Cat produced a potentially dangerous ski for 2 seasons. Thankgoodness they were only on a few models. I hope no one paid a Dealer to fix their mistake! )

A minor glitch has surfaced regarding the ultra trick and lightweight plastic composite skis found on the ZRT 800, ZRT 600, ZR 440. An error in how the wear bars mate to the ski bottom is causing some bars to not fully “seat”. The problem is occurring at the front of the bar where it should retreat up into a notch located on the ski. (There was no notch in the 1994 or 95 skis so none of the bars could seat.) In reality, the problem is a rather common occurrence. Other ski makers have had similar problems with plastic skis and wear bar mating for some time. (Name one other ski that had this problem.) Fortunately our sources say the fix is quick and easy. Simply loosen the nuts, apply heat at the right locations and bend the end of the wear bar into its new home. With the right tools, weekend motorheads can cure the problem in minutes. If you’re not up to the task, bring your scoot to your friendly Cat dealer and he’ll have you back on the trail in time.

New Cat owners should check the mate between ski and wear bar on the light, tight and just so right factory issue composite skis.

There was no notch in this 1995, ZRT-800 plastic ski.

The saddle spacers in the back 3 bolt holes tapered inward but created a 1/16” gap between the host bar and the keel. The front hole in the keel was so small the weld deposit around the bolt increased the gap to a full 1/8” at the very front.

This was the interim 1996 ski with a groove from the front too the 2nd bolt hole. Before the end of the season I bought the up-dated version which stayed the same through 2001.




Service Bulletin


Model: ZRT 600 • 800 - ZR440


Subject: Ski Drag Modification


Date: December 1, 1994


CONDITION: The front end of the ski skag may catch on stationary objects which could result in a loss of control or A-arm and front end damage.

SOLUTION: If the snowmobile has already been set-up, tip the snowmobile on its side; then working on the upper ski, loosen the front skag lock nut until there is approximately 1/8 inch clearance between the bottom of the skag and the ski bottom.

Using either a propane torch or a gas welder with a small tip, preheat the front 3 inches of the skag. Move the torch back and forth on the skag heating this 3 inch area evenly and directing the flame onto the skag and not the ski.

Continue to heat the skag until the 3 inch area is starting to give off a slight smoke; then quickly tighten the front skag lock nut and draw the front of the skag into the plastic ski bottom until ½ of the diameter of the skag end is imbedded in the ski bottom.

The skag must be hot enough so it melts its way down into the ski bottom as the lock nut is tightened. If the skag isn’t melting the plastic as the lock nut is tightened, you must reheat the front 3 inch area of the skag to a hotter temperature (until the end of the skag can be drawn half way down into the ski bottom).

Using a large flat blade screwdriver, remove the excess melted plastic from around the end of the skag and allow to cool. Repeat the same procedure on the opposite side.

NOTE: If the skis have not been installed, perform this procedure with the ski held upside down in a vise.


WARRANTY: A group warranty claim of up to 10 serial numbers will be accepted. Write 95-07 in the failure code section of the warranty claim. A labor allowance of 0.4 hours will be paid per snowmobile.

NOTE: If any of the affected snowmobiles have been delivered, please contact each owner and have them bring their snowmobile in for this very important modification.

Arctco,Inc. PO Box 810, 600 South Brooks Ave, Thief River Falls, MN, 218-681-8558


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