Artic Cat® ZR Installation

A man riding in an Arctic Cat® snowmobile in the snowy forest.

Arctic Cat® ZR Installation

When you put your snowmobile to good use, you’ll eventually find yourself needing to change or upgrade your tracks. In order to do this, you may need to install tunnel extensions. Arctic Cat® ZR snowmobiles are a popular and reliable choice, so below you’ll find a quick guide for preparation for tunnel extension installation on the ZR series machines.

With your extensions installed, you’ll be able to utilize longer tracks! Visit us in Lake Lillian, MN, to choose your next tracks and learn about more ways to improve your snowmobile experience.


’99 & Newer ZR, ZRT, Thundercat, ZL & EXT Tunnel Extensions

Arctic Cat 121” to 136” or 144”

Tunnel Preparation:

  1. Remove bumper / snow flap assembly. You can either loosen the seat and prop up or completely remove seat assembly. It can sometimes be easier to just remove the seat for tunnel extension installation.
  2. After the snow flap / bumper assembly is removed, the aluminum close off or end cap in the back of the tunnel will be visible. This will have to be removed in order for the tunnel extension to be placed on the inside of your existing tunnel. Care needs to be taken when removing this close off. The exposed edge on the back of the tunnel will be visible so you will want to use a straight edge or square to mark a straight line prior to cutting.
  3. Your tunnel extension will come with a hardware package. The small headed 3/16” rivets are to be placed around the top and sides of the extension. Failure to use all of them when attaching could result in product failure.
  4. Place the tunnel extension inside of the snowmobile tunnel and use clamps to hold in place. There are tabs on the leading edge that will be placed over the back end of the snowmobiles running board. These will be held in place by the ¼” bolts/nuts/washers provided. There are numerous pre-marked holes in the tunnel extension where rivets are meant to be placed. Drill these out to 3/16” and install rivets.
  5. Once main tunnel extension if fastened, take the U-shaped hose protector that is included, place over exposed hose in the top rear of tunnel and drill / rivet into place.
  6. Your bumper / snow flap assembly can now be reattached to the tunnel extension. The seat can also be installed at this time as well.


Note: Our ’99 and newer tunnel extension will not work for ’98 and older applications. The sides of the ’98 and older snowmobiles do not go back as far and there would be an exposed area where the tunnel extension and existing tunnel would not overlap. 

Arctic Cat R Installation Pic


Tracks USA

Please feel free to contact us or stop in today! Call us at (320) 382-6128 or contact us below.