Arctic_cat_2007_400_500_650_700_service_manual Arctic Cat 2007 400 500 650 700 Service Manual
User Manual: arctic_cat_2007_400_500_650_700_service_manual
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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2007 Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented applications. Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To service models not included in this manual, please refer to the following publications: • • • • • 2007 Y-12 Service Manual 2007 DVX/Utility 250 Service Manual 2007 DVX 400 Service Manual 2007 Prowler Service Manual 2007 700 Diesel Service Manual This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of each component or system by carefully studying the complete manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc. © 2006 Arctic Cat Inc. www.mymowerparts.com ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 August 2006 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Foreword Click on the red text to go. Section 1. General Information 1 2. Periodic Maintenance/Tune-Up 2 3. Engine/Transmission 3 4. Fuel/Lubrication/Cooling 4 5. Electrical System 5 6. Drive System 6 7. Suspension 7 8. Steering/Frame 8 9. Controls/Indicators 9 10. Aids for Maintenance 10 11. Troubleshooting 11 www.mymowerparts.com FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION 1 TABLE OF CONTENTS General Specifications (400/400 TRV - Automatic Transmission)............. 1-2 General Specifications (400 - Manual Transmission)................................ 1-3 General Specifications (500 - Manual Transmission)................................ 1-4 General Specifications (500 - Automatic Transmission)............................ 1-5 General Specifications (650 H1/650 H1 TBX/650 H1 TRV)...................... 1-6 General Specifications (700 EFI) .............................................................. 1-7 Break-In Procedure ................................................. 1-8 Gasoline - Oil - Lubricant ........................................ 1-8 Genuine Parts ......................................................... 1-9 Preparation For Storage .......................................... 1-9 Preparation After Storage...................................... 1-10 www.mymowerparts.com 1-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* (400/400 TRV - Automatic Transmission) MISCELLANY CARBURETOR Type Keihin CVK34 Main Jet 135 Slow Jet 38 Pilot Screw Setting (turns) 1 3/4 Jet Needle NAZG Idle RPM (engine warm) 1250-1350 Starter Jet 75 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) Less than 1 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage Magneto Coil Resistance (primary/ 250-375 DC volts CDI) (terminal to ground) (trigger) 160-240 ohms (green to blue) (source) Less than 1 ohm (yellow to white) (charging) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) 5.04-7.56 volts (green to blue) (source) 0.7-1.05 volts (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 220W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) www.mymowerparts.com 1-2 Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) 20.8 L (5.5 U.S. gal.) - TRV Rear Drive Capacity 250 ml (8.5 fl oz)** Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)*** Engine Oil Capacity 3.08 L (3.25 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 5W-30 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width 28.5 mm (1.12 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* (400 - Manual Transmission) MISCELLANY CARBURETOR Type Keihin CVK34 Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Main Jet 135 Rear Drive Capacity 250 ml (8.5 fl oz)** Slow Jet 38 Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)*** Pilot Screw Setting (turns) 1 3/4 Engine Oil Capacity 3.08 L (3.25 U.S. qt) Jet Needle NAZG Gasoline (recommended) 87 Octane Regular Unleaded Idle RPM (engine warm) 1250-1350 Engine Oil (recommended) SAE 5W-30 Starter Jet 75 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Float Arm Height 17 mm (0.7 in.) Brake Fluid DOT 4 Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) Less than 1 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ 250-375 DC volts CDI) (terminal to ground) Magneto Coil Resistance (trigger) 160-240 ohms (green to blue) (source) Less than 1 ohm (yellow to white) (charging) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) 5.04-7.56 volts (green to blue) (source) 0.7-1.05 volts (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 1 * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. 220 W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) www.mymowerparts.com 1-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* (500 - Manual Transmission) MISCELLANY CARBURETOR Keihin CVK36 Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Main Jet 138 Coolant Capacity 2.9 L (3.0 U.S. qt) Slow Jet 40 Differential Capacity 275 ml (9.3 fl oz)** Pilot Screw Setting (turns) 1 3/4 Rear Drive Capacity 250 ml (8.5 fl oz)*** Jet Needle NFKG Engine Oil Capacity 3.4 L (3.5 U.S. qt) Idle RPM (engine warm) 1250-1350 Gasoline (recommended) 87 Octane Regular Unleaded Starter Jet 85 Engine Oil (recommended) SAE 5W-30 Float Arm Height 17 mm (0.7 in.) Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Type ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Ignition Coil Peak Voltage (primary/ CDI) Magneto Coil Resistance (trigger) (source) (charging) Magneto Coil Peak Voltage (trigger) (source) Stator Coil Output (no load) Magneto Output (approx) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) 140-215 DC volts (terminal to ground) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) 325W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) www.mymowerparts.com 1-4 * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* (500 - Automatic Transmission) CHASSIS CARBURETOR Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) Type Keihin CVK36 Main Jet 138 Slow Jet 40 Pilot Screw Setting (turns) 1 3/4 Jet Needle NFKG Idle RPM (engine warm) 1250-1350 Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Starter Jet 85 Coolant Capacity 2.9 L (3.0 U.S. qt) Float Arm Height 17 mm (0.7 in.) Differential Capacity 275 ml (9.3 fl oz)** Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.5 L (2.6 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Engine Oil (recommended) SAE 5W-30 Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Differential/Rear Drive Lubricant Spark Plug Cap 8000-12,000 ohms SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 38 mm (1.33 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Ignition Coil Resistance Ignition Coil Peak Voltage (primary) Less than 1 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) (primary/ 140-215 DC volts CDI) (terminal to ground) Magneto Coil Resistance (trigger) 160-240 ohms (green to blue) (source) Less than 1 ohm (yellow to white) (charging) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) 4.2-6.3 volts (green to blue) (source) 0.40-0.62 volt (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 1 MISCELLANY * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. 325W @ 5000 RPM www.mymowerparts.com 1-5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* (650 H1/650 H1 TBX/650 H1 TRV) CARBURETOR Type Keihin CVK36 Main Jet 132 Slow Jet 40 Pilot Screw Setting (turns) 1 1/4 Jet Needle NFKS Idle RPM (engine warm) 1250-1350 Starter Jet 85 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) 20.8 L (5.5 U.S. gal.) - TBX/ TRV Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Ignition Timing 10° BTDC @ 1500 RPM Engine Oil Capacity 3.4 L (3.5 U.S. qt) Spark Plug Type NGK CR6E Gasoline (recommended) 87 Octane Regular Unleaded Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Engine Oil (recommended) SAE 5W-30 Spark Plug Cap 4000 ohms Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Ignition Coil Resistance Ignition Coil Peak Voltage (primary) Less than 1 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) (primary/ 142.4-213.6 DC volts CDI) (terminal to ground) Magneto Coil Resistance (trigger) 160-240 ohms (green to blue) (source) Less than 1 ohm (yellow to white) (charging) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) 4.2-6.3 volts (green to blue) (source) 0.40-0.62 volt (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) www.mymowerparts.com 1-6 325W @ 5000 RPM Belt Width 35.5 mm (1.40 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* (700 EFI) CHASSIS FUEL INJECTION Type Electronic Throttle Body Idle RPM (engine warm) 1200-1400 Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) ELECTRICAL Spark Plug Type Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.45 L (2.6 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Stator Coil (crankshaft position 150-250 ohms Resistance sensor) (blue to white) (charging) Less than 1 ohm (yellow to yellow) Engine Oil (recommended) SAE 5W-30 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Crankshaft Position Sensor Peak Voltage Drive Belt Width (minimum) 35.6 mm (1.40 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance Ignition Coil Peak Voltage Stator Coil Output 1 MISCELLANY NGK CR6E (primary) Less than 1 ohm (terminal (+) to terminal (-)) (secondary) 12k-19k ohms (plug cap to terminal (+)) (ECU) 80 volts or more (wire (+) to wire (-)) 5.0 volts or more (blue to white) (no load) 75 AC volts @ 5000 RPM (yellow to yellow) * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. www.mymowerparts.com 1-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Break-In Procedure A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. During the break-in period (or whenever the brake pads are replaced), the hydraulic brake pads must be burnished. Slow disc-speed hydraulic brakes must be properly burnished in order to achieve maximum stopping power. ! CAUTION BRAKE PADS MUST BE BURNISHED TO ACHIEVE FULL BRAKING EFFECTIVENESS. Braking distance will be extended until brake pads are properly burnished. TO PROPERLY BURNISH THE BRAKES, USE FOLLOWING PROCEDURE: • Choose an area sufficiently large to safely accelerate ATV to 30 mph and to brake to a stop. • Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph. • Repeat procedure five times until brakes are burnished. • This procedure burnishes the brake pads, stabilizes the pad material, and extends the life of the brake pads. ! WARNING Do not attempt sudden stops or put the ATV into a situation where a sudden stop will be required until the brake pads are properly burnished. www.mymowerparts.com 1-8 NOTE: Do not be reluctant to heat up the brake pads during the burnishing procedure. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners. Gasoline - Oil Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or 5% MTBE are acceptable gasolines. When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system. ! CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. RECOMMENDED ENGINE/ TRANSMISSION OIL ! CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils. The recommended oil to use is Arctic Cat 4-Cycle Engine Oil or an equivalent oil which is rated SE, SF, or SG under API service classification. These oils meet all of the lubrication requirements of the Arctic Cat ATV engine. The recommended engine oil viscosity is SAE 5W-30. Ambient temperature should determine the correct weight of oil. See the following viscosity chart for details. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area. ! WARNING Do not overflow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank. OILCHARTC RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT Tighten the gas tank cap securely after filling the tank. ! WARNING Do not over-fill the gas tank. The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives. ! CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage. Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precisionmade to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description. FILLING GAS TANK Preparation For Storage ! WARNING Always fill the gas tank in a well-ventilated area. Never add fuel to the ATV gas tank near any open flames or with the engine running. DO NOT SMOKE while filling the gas tank. ! CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. Arctic Cat recommends the following procedure to prepare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake. ATV0049B www.mymowerparts.com 1-9 1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine. Install the air filter and housing cover. ! CAUTION Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of troublefree riding. Arctic Cat recommends the following procedure to prepare the ATV. If the interior of the air filter housing is dirty, clean the area before starting the engine. 1. Clean the ATV thoroughly. 4. On carbureted models, drain the carburetor float chamber. 2. Clean the engine. Remove the cloth from the exhaust system. 5. Plug the exhaust hole in the exhaust system with a clean cloth. 3. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. 4. Change the engine/transmission oil and filter. 7. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications (see Section 10). 8. On liquid cooled models, fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. 9. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 10. Store the ATV indoors in a level position. ! CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting. 5. On liquid cooled models, check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables. ! CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system. ! CAUTION Connect the positive battery cable first; then the negative. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications (see Section 10). 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug. Clean or replace as necessary. www.mymowerparts.com 1-10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS www.mymowerparts.com 2 Periodic Maintenance Chart .................................... 2-2 Lubrication Points.................................................... 2-3 Battery..................................................................... 2-3 Fuses ...................................................................... 2-4 Air Cleaner/Filter ..................................................... 2-4 Valve/Tappet Clearance (Feeler Gauge Procedure) ................................... 2-6 Valve/Tappet Clearance (Valve Adjuster Procedure) .................................. 2-6 Valve/Tappet Clearance (700 EFI)........................... 2-7 Testing Engine Compression................................... 2-9 Spark Plug............................................................. 2-10 Muffler/Spark Arrester ........................................... 2-10 Gas/Vent Hoses .................................................... 2-11 Adjusting Throttle Cable ........................................ 2-11 Adjusting Engine RPM (Idle) ................................. 2-11 Engine/Transmission Oil - Filter - Strainer ............ 2-12 Front Differential/Rear Drive Lubricant .................. 2-14 Adjusting Clutch (400/500 Manual Transmission) ......................... 2-14 Tires ...................................................................... 2-15 Steering Components ........................................... 2-15 Driveshaft/Coupling ............................................... 2-15 Suspension/Shock Absorbers/Bushings ............... 2-16 Nuts/Bolts/Cap Screws.......................................... 2-16 Ignition Timing ....................................................... 2-16 Headlight/Taillight-Brakelight ................................. 2-16 Switches ................................................................ 2-17 Shift Lever ............................................................. 2-18 Frame/Welds/Racks .............................................. 2-19 Electrical Connections........................................... 2-19 Hydraulic Brake Systems ...................................... 2-20 Burnishing Brake Pads .......................................... 2-21 Coolant (500/650 H1/700 EFI) .............................. 2-22 Checking/Replacing V-Belt ................................... 2-22 Adjusting Differential Lock Cable........................... 2-24 Exhaust Chart ....................................................... 2-25 Intake Chart........................................................... 2-26 2-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust C = Clean D = Drain Periodic Maintenance Chart Item Battery Initial Service After Break-In (First Mo or 100 Mi) Every Day I Every Month or Every 100 Miles Every 3 Months or Every 300 Miles I = Inspect L = Lubricate R = Replace Every 6 Months or Every 500 Miles I Fuses I Valve/Tappet Clearance I I R C* R I Engine Compression A I I I Muffler/Spark Arrester R (4000 Mi or 18 Mo) C Gas/Vent Hoses I I Throttle Cable I I R R (2 Yrs) Carburetor Float Chamber (Carbureted Models) Engine Idle RPM (Carbureted Models) As Needed C I Air Filter/Drain Tube Spark Plug Every Year or Every 1500 Miles C-L A-R I A D* I Engine-Transmission Oil Level I A Engine-Transmission Oil/Filter R Oil Strainer I R* Front Differential/Rear Drive Lubricant I Clutch (Manual) I Tires/Air Pressure I Steering Components I V-Belt (Automatic) I Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) I l* Nuts/Cap Screws/Screws I I R I C R (4 Yrs) l I A I R I R l R R I Ignition Timing A I Headlight/Taillight-Brakelight I I Switches I I R R Shift Lever I A-L Recoil Starter (Except certain 650 H1 models) I C-R Handlebar Grips I R Handlebars I I R Gauges/Indicators I I R Frame/Welds/Racks I I l Electrical Connections l Complete Brake System (Hydraulic & Auxiliary) I Brake Pads I I C C L-R I* R Brake Fluid I I R (2 Yrs) Brake Hoses I I R (4 Yrs) Coolant/Cooling System I I * Service/Inspect more frequently when operating in adverse conditions. www.mymowerparts.com 2-2 R (2 Yrs) FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Lubrication Points It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components using the following list as reference. A. Throttle Lever Pivot/Cable Ends B. Brake Lever Pivot/Cable Ends C. Auxiliary Brake Cable Ends D. Shift Lever Cable End E. Idle RPM Screw (Carburetor) (If Applicable) ! WARNING Avoid spillage and contact with skin, eyes, and clothing. ! CAUTION Do not charge the battery while it is in the ATV with the battery terminals connected. 3. Remove the vent plugs; then (if necessary) fill the battery with distilled water to the upper level indicated on the battery. 4. Trickle charge the battery at 1.5 amps for 10 hours. 2 ! CAUTION Never exceed the standard charging rate. Battery The level of the battery fluid must be kept between the upper and lower level lines at all times. If the level drops below the lower level line, add only distilled water until it reaches upper level line. ! WARNING Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. If the battery is discharged, remove the battery from the ATV and charge the battery at 1.5 amps for 10 hours. To remove and charge the battery, use the following procedure. ! WARNING Anytime service is performed on a battery, the following must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear safety glasses. Protect skin and clothing when handling a battery. When servicing battery in enclosed space, keep the area well-ventilated. Make sure battery venting is not obstructed. 5. After charging, check fluid level and fill with distilled water as necessary; then install vent plugs. ! CAUTION Before installing the battery, make sure the ignition switch is in the OFF position. 6. Place the battery into position in the ATV and secure with the hold-down bracket. 7. Attach the vent tube and check the vent tube to make sure it is not crimped or obstructed in any way and that it is properly routed through and secured to the frame. 8. Connect cables to the proper terminals: positive cable to the positive terminal (+) and negative cable to the negative terminal (-). Connect the negative cable last. ! CAUTION Connecting cables in reverse (positive to negative and negative to positive) can cause serious damage to the electrical system. 1. Remove the battery hold-down bracket. 2. Remove the negative battery cable; then remove the positive cable and the battery vent tube. Remove the battery from the ATV. Care should be taken not to damage the vent tube. www.mymowerparts.com 2-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Fuses Always replace a blown fuse with a fuse of the same type and rating. The fuses are located in a power distribution module under the seat. If there is any type of electrical system failure, always check the fuses first. NOTE: To remove a fuse, compress the locking tabs on either side of the fuse case and lift out. 400/400 TRV/500 Auto Air Cleaner/Filter The air filter inside the air filter housing must be kept clean to provide good engine power and gas mileage. If the ATV is used under normal conditions, service the filter at the intervals specified. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently. Use the following procedure to remove the filter and inspect and/or clean it. CLEANING AND INSPECTING FILTER ! CAUTION 0411-828 400/500 Manual Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can damage the engine. 1. Remove the seat; then remove the appropriate reinstallable rivets securing the storage compartment. 0411-837 650 H1/650 H1 TBX/650 H1 TRV CF145C 1411-502 700 EFI 1411-311 www.mymowerparts.com 2-4 CD710C FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. On the 400, remove the storage compartment assembly by elevating the rear of the compartment, moving it rearward, and lifting it off. FI033 5. Remove the air filter/filter screen assembly and separate the foam filter from the screen. CF143A 3. On the 500/650 H1/700 EFI, raise the storage compartment cover; then slide the cover forward and off the compartment. Remove the storage compartment. 6. Fill a wash pan larger than the filter with a non-flammable cleaning solvent; then dip the filter in the solvent and wash it. NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat. 7. Dry the filter. 8. Put the filter in a plastic bag; then pour in air filter oil and work the filter. Reattach the filter to the filter screen. ! CAUTION CD669 4. Unsnap the four spring-clip fasteners (400/500/650 H1) or remove two wing-nuts (700 EFI); then remove the air filter cover. A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn. 9. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the carburetor (if equipped). 10. Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter screen down. CD675A CD674 www.mymowerparts.com 2-5 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the air filter housing cover and secure with the retaining clips (400/500/650 H1) or wing-nuts (700 EFI). 12. Install the storage compartment; then secure with the reinstallable rivets. CHECKING AND CLEANING DRAINS NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 3. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment. 1. Inspect one-way drains beneath the main housing for debris and for proper sealing. ! CAUTION The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve component damage. VALVE/TAPPET CLEARANCE (400/500) Intake 0.05-0.10 mm (0.002-0.004 in.) Exhaust (400) 0.22-0.27 mm (0.009-0.011 in.) Exhaust (500) 0.17-0.22 mm (0.007-0.009 in.) VALVE/TAPPET CLEARANCE (650 H1) KX045A 2. Replace any one-way drain that is cracked or shows any signs of hardening or deterioration. Intake 0.1016 mm (0.004 in.) Exhaust 0.1524 mm (0.006 in.) ! CAUTION The one-way drain to the right is the clean air section of the filter housing. Any leak of this one-way drain will allow dirt into the engine intake causing severe engine damage. 3. Wipe any accumulation of oil or gas from the filter housing and one-way drains. CC007DB Valve/Tappet Clearance (Feeler Gauge Procedure) NOTE: For the 700 EFI, see Valve/Tappet Clearance (700 EFI) in this section. To check and adjust valve/tappet clearance, use the following procedure. 1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). 2. Rotate the crankshaft to the TDC position on the compression stroke. www.mymowerparts.com 2-6 4. Install the timing inspection plug. 5. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. Valve/Tappet Clearance (Valve Adjuster Procedure) NOTE: For the 700 EFI, see Valve/Tappet Clearance (700 EFI) in this section. To check and adjust valve/tappet clearance, use the following procedure. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: On the TBX/500/650 H1, the seat, storage compartment cover assembly, compartment box, air filter/filter housing, and left-side/right-side splash panels must be removed for this procedure. 1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). 8. Place the two tappet covers with O-rings into position; then tighten the covers securely. 9. Install the spark plug; then install the timing inspection plug. Valve/Tappet Clearance (700 EFI) To check and adjust valve/tappet clearance, use the following procedure. NOTE: The seat, heat shields, splash panels, front rack, and front fenders must be removed for this procedure (see Section 8). CF005 1. Remove the spark plug cap/high tension lead; then using compressed air, blow any debris from around the spark plug. 2. Rotate the crankshaft to the TDC position on the compression stroke. ! WARNING NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. Always wear safety glasses when using compressed air. NOTE: Use Valve Clearance 0444-078) for this procedure. Adjuster (p/n 2. Remove the recoil starter assembly; then remove the valve timing inspection plug and the cylinder head cover. 3. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. 4. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. 5. Align the valve adjuster handle with one of the marks on the valve adjuster dial. 6. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained. NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance. FI039A 3. Using an appropriate bar, rotate the engine through two full revolutions; then while on the compression stroke, align the TDC line on the starter clutch with the index mark on the crankcase. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark. 7. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. www.mymowerparts.com 2-7 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI041A NOTE: Rotating the engine ensures that any trapped oil is squeezed from the tappets and tappet shims. Oil trapped in these areas could result in a false valve clearance reading. FI054 7. Fold a suitable towel and use it to plug the camshaft drive passageway; then using a magnet, remove the tappet and shim from the appropriate valve. 4. Using an appropriate thickness gauge, measure and record the clearance of both intake valves; then measure and record the clearance of both exhaust valves. Valve clearance must be within specifications. VALVE/TAPPET CLEARANCE (700 EFI) Intake 0.10-0.20 mm (0.004-0.008 in.) Exhaust 0.20-0.30 mm (0.008-0.012 in.) FI055 FI046 AT THIS POINT If valve clearance is within specifications, proceed to step 12. 5. Identify the valves that are not within specifications; then remove the corresponding camshaft (see Section 3 - Removing Top-Side Components). ! CAUTION When removing camshaft holders, use extreme care not to drop alignment pins into the engine. 6. Mark the valve tappets in order to return them to the proper position during assembly. www.mymowerparts.com 2-8 FI056 ! CAUTION If the camshaft passageway is not plugged, tappet shims could fall into the engine crankcase. 8. Note the three digit number on the surface of the tappet shim; then refer to the appropriate tappet shim selection table at the end of this section for the correct replacement. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Install the valve timing inspection plug and tighten securely; then install the recoil starter assembly and secure with the four cap screws coated with blue Loctite #242. Tighten to specifications (see Section 10). 14. Install the spark plug cap/high tension lead, front fenders, front rack, and splash panels; then install the heat shields and seat making sure the seat locks securely. FI051 A. Measured tappet clearance from step 4 in vertical column on left. B. Present shim size horizontal row at the top. C. Match measured clearance in vertical column with current shim size in horizontal row to find recommended replacement size. 9. Apply engine oil to both surfaces of the tappet shim; then place the shim on the valve with the numbers toward the tappet. Testing Engine Compression To test engine compression, use the following procedure. 1. Remove the high tension lead from the spark plug. 2. Using compressed air, blow any debris from around the spark plug. ! WARNING Always wear safety glasses when using compressed air. 3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. ! CAUTION FI053 10. Install the tappet on the appropriate valve; then install the camshaft. 11. Using an appropriate bar, rotate the engine through two full revolutions; then rotate to TDC on the compression stroke and check the valve tappet clearance. NOTE: Rotating the engine ensures that any excess oil is squeezed from the tappets and tappet shims. Oil trapped in these areas could result in a false valve clearance reading. 12. Using a new gasket, apply Three Bond Sealant to the camshaft end caps of the cylinder head cover gasket; then install the cylinder head cover and tighten the four cap screws to specifications (see Section 10). www.mymowerparts.com On the 700 EFI, do not ground the spark plug on the cylinder head cover. The cover is made of magnesium and any contact with spark or electrical arc will severely pit the surface. 4. Attach the Compression Tester Kit (p/n 0444-213). NOTE: The engine must be warm and the battery must be fully charged for this test. 5. While holding the throttle lever in the full-open position, crank the engine over with the electric starter until the gauge shows a peak reading (five to 10 compression strokes). NOTE: For the 400, the compression should be within a range of 95-115 psi in the full-open throttle position. For the 500/650 H1, the compression should be within a range of 70-85 psi in the full-open throttle position. For the 700 EFI, the compression should be within a range of 130-155 psi in the full-open throttle position. 2-9 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. If compression is abnormally low, inspect the following items. A. Verify starter cranks engine over at normal speed (approximately 400 RPM). B. Gauge functioning properly. C. Throttle lever in the full-open position. D. Valve/tappet clearance correct. E. Valve not bent or burned. F. Valve seat not burned. ATV0052B NOTE: To service valves, see Section 3. 7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole, reattach the gauge, and retest compression. 8. If compression is now evident, service the piston rings (see Section 3). Spark Plug A light brown insulator indicates that a plug is correct. A white or dark insulator indicates that the engine may need to be serviced or the carburetor (if equipped) may need to be adjusted. To maintain a hot, strong spark, keep the plug free of carbon. When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once the washer contacts the cylinder head. Muffler/Spark Arrester The muffler has a spark arrester which must be periodically cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure. ! WARNING Wait until the muffler cools to avoid burns. 1. Remove the three cap screws securing the spark arrester assembly to the muffler; then loosen and remove the arrester. ATV-0051 ! CAUTION Before removing a spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug. Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for proper ignition. Use a feeler gauge to check the gap. CF105A 2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen. NOTE: If the screen or gasket is damaged in any way, it must be replaced. www.mymowerparts.com 2-10 3. Install the spark arrester assembly with gasket; then secure with the three cap screws. Tighten to 0.6 kg-m (4.0 ft-lb). FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF104 ATV-0047 3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. Gas/Vent Hoses 2 Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the carburetor/throttle body vent hose. Make certain that the vent hose is securely connected to the carburetor/throttle body and the opposite end is always open. Adjusting Engine RPM (Idle) NOTE: The idle RPM is not adjustable on the 700 EFI. To properly adjust the idle RPM, a tachometer is necessary. To adjust idle RPM, use the following procedure. Adjusting Throttle Cable NOTE: The idle adjustment screw is located on the right-hand side of the carburetor. To adjust the throttle cable free-play, follow this procedure. 1. Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster. 1. With the transmission in neutral, start the engine and warm it up to normal operating temperature. 2. Turn the idle adjustment screw clockwise one turn past the recommended RPM setting; then turn it counterclockwise to 1250-1350 RPM. AL611D 2. Turn the adjuster until the throttle cable has proper free-play of 3-6 mm (1/8-1/4 in.) at the lever. AF920D ! WARNING Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM. www.mymowerparts.com 2-11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission Oil - Filter - Strainer 4. On the 400/500, remove the oil filter plug from the filter mounting boss (located on the front side of the transmission case) and allow the filter to drain completely. Install the plug and tighten securely. OIL - FILTER 5. On the 700 EFI, remove the left-side engine cover and the left-front inner fender panel. Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is changed so the oil will drain easily and completely. 6. Using the adjustable Oil Filter Wrench (p/n 0644-389) and a suitable wrench, remove the old oil filter. NOTE: Clean up any excess oil after removing the filter. 1. Park the ATV on level ground. 2. Remove the oil level stick/filler plug. 7. Apply oil to a new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten securely. NOTE: Install a new O-ring each time the filter is replaced. 8. Install the engine drain plug and tighten to specifications. Pour the specified amount of the recommended oil in the filler hole. Install the oil level stick/filler plug. ! CAUTION ATV-0075 Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils. 9. Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes. 10. Turn the engine off and wait approximately one minute. 0735-505 3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan. 11. Unscrew the oil level stick and wipe it with a clean cloth. 12. Install the oil level stick until the threads touch engine case. NOTE: The oil level stick should not be threaded into the case for checking the oil level. 13. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. www.mymowerparts.com 2-12 733-441A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is above the “L” mark but not higher than the “F” mark. CC163D AT THIS POINT To service oil strainer, see Section 3. ATV-0100 14. Inspect the area around the drain plug and oil filter for leaks. 4. Place the oil strainer into position beneath the crankcase and secure with the Phillips-head cap screws. Tighten securely. 15. On the 700 EFI, install the left-side engine cover and the left-front inner fender panel. STRAINER To check the oil strainer, use the following procedure. 1. Remove the belly panel. 2. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the O-ring. CC163D 5. Place the strainer cap into position on the strainer making sure the O-ring is properly installed; then secure with the cap screws. Tighten securely. CC091D 3. Remove the two Phillips-head cap screws securing the strainer. CC091D 6. Install the belly panel. www.mymowerparts.com 2-13 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Differential/Rear Drive Lubricant Check and change the lubricant according to the Periodic Maintenance Chart. When changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, remove the rear drive filler plug; the lubricant level should be 1 in. below the threads of the plug. If low, add SAE approved 80W-90 hypoid gear lube as necessary. To change the lubricant, use the following procedure. 1. Place the ATV on level ground. 737-651B 4. After all the oil has been drained, install the drain plugs and tighten to specifications (see Section 10). 5. Pour the appropriate amount of recommended oil into the filler hole. 6. Install the fill plugs. 2. Remove each oil fill plug. NOTE: If the differential/rear drive oil is contaminated with water, inspect the drain plug, filler plug, and/or bladder. ! CAUTION Water entering the outer end of the axle will not be able to enter the rear drive unless the seals are damaged. AL677C 3. Drain the oil into a drain pan by removing in turn the drain plug from each. Adjusting Clutch (400/500 Manual Transmission) To adjust the clutch, use the following procedure. 1. Using an impact driver, remove the screws securing the cover and remove the cover. Account for the O-ring. ATV0082A AM600D www.mymowerparts.com 2-14 2. Loosen the jam nuts securing adjustment screw #1 (forward) and adjustment screw #2 (rearward). FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0.35 kg-cm² (5.0 psi). A low-pressure gauge is provided in the tool kit to measure the air pressure in the tires. Check the air pressure in all tires before each use of the ATV. Steering Components CC037D 3. Rotate adjustment screw #1 counterclockwise until it stops. The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding. D. Ball joints not worn, cracked, or damaged. CC038D 4. Rotate adjustment screw #2 alternately clockwise and counterclockwise to ensure free movement without binding; then lock the jam nut securing adjustment screw #2. 5. Rotate adjustment screw #1 clockwise 1/8 turn; then lock the jam nut securing adjustment screw #1. NOTE: At this point the clutch should be adjusted correctly. Test to ensure accurate adjustment. 6. Install the cover making sure the O-ring is properly positioned; then secure with the screws. E. Tie rods not bent or cracked. F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing. Driveshaft/Coupling The following drive system components should be inspected periodically to ensure proper operation. A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn. Tires TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed (see Section 1). Do not under any circumstances substitute tires of a different type or size. ! WARNING Always use the size and type of tires specified. Always maintain proper tire inflation pressure. www.mymowerparts.com 2-15 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension/Shock Absorbers/Bushings If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil/CKP sensor bracket may be bent or damaged, or the CDI unit/ECU may be faulty. The following suspension system components should be inspected periodically to ensure proper operation. Headlight/TaillightBrakelight A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. D. Shock absorber eyelets not broken, bent, or cracked. E. Shock absorber eyelet bushings not worn, deteriorated, cracked, or missing. F. Shock absorber spring not broken or sagging. Nuts/Bolts/Cap Screws Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications (see Section 10). Ignition Timing NOTE: The 700 EFI rotor/flywheel does not have timing marks; therefore, timing cannot be verified. The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components. To verify ignition timing, use the following procedure. 1. Attach the Timing Light (p/n 0644-296) to the spark plug high tension lead; then remove the timing inspection plug from the left-side crankcase cover. 2. Using the Tachometer (p/n 0644-275), start the engine and run at 1500 RPM; ignition timing should be 10° BTDC. 3. Install the timing inspection plug. www.mymowerparts.com 2-16 Each time the ATV is used, lights should be checked for proper function. Rotate the ignition switch to the lights position; the headlights and taillight should illuminate. Test the brakelight by compressing the brake lever. The brakelight should illuminate. HEADLIGHT NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb. ! WARNING Do not attempt to remove the bulb when it is hot. Severe burns may result. To replace the headlight bulb, use the following procedure. 1. Remove the wiring harness connector from the back of the headlight. 2. Grasp the bulb housing, turn it counterclockwise, and remove the bulb. 3. Install the new bulb into the housing and rotate it completely clockwise. 4. Install the wiring harness connector. TAILLIGHT-BRAKELIGHT To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface. CF135A 2. Pull the bulb straight out of the socket; then insert a new bulb. ATV-0070C 7. Adjust each headlight by turning the adjuster knob clockwise to raise the beam or counterclockwise to lower the beam. CF132A 3. Insert the bulb socket assembly into the housing and turn it clockwise to secure. CHECKING/ADJUSTING HEADLIGHT AIM CD714A The headlights can be adjusted vertically and horizontally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming. 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface). NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. 2. Measure the distance from the floor to the mid-point of each headlight. 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface. 4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights. 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. Switches Each time the ATV is used, switches should be checked for proper operation. Use the following list for reference. A. Ignition switch — engine will start. B. Emergency stop switch — engine will stop. C. Reverse switch — reverse indicator light will illuminate. D. Hi/Lo switch — headlight beam bright and dim. E. Brake switches — rear brakelight will illuminate. www.mymowerparts.com 2-17 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 If the reverse light does not illuminate when shifted to the reverse position, the switch may be faulty, the fuse may be blown, the bulb may be faulty, a connection may be loose or corroded, or the lever may need adjusting. To adjust, proceed to Adjusting Shift Lever. Shift Lever CHECKING ADJUSTMENT ADJUSTING SHIFT LEVER 400/500 Manual Transmission CF150B KEY 1. 2. 3. 4. 5. 6. 7. Handle Push Clip Shift Plate Stamped Nut Lever Spring Axle 8. 9. 10. 11. 12. 13. 14. Nut O-Ring Axle O-Ring Cap Screw Washer Nut 15. 16. 17. 18. 19. Rod End Linkage Bushing Washer E-Ring 0739-739 CF238A CF130A Stop the ATV completely and shift the transmission into the R position. The reverse gear indicator light should be illuminated. ! WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop suddenly throwing the operator from the ATV. www.mymowerparts.com 2-18 400/500 Automatic Transmission/ 650 H1/700 EFI KEY 1. 2. 3. 4. 5. 6. 7. Handle Push Clip Shift Plate Stamped Nut Lever Spring Axle 8. 9. 10. 11. 12. 13. 14. Nut O-Ring Axle O-Ring Cap Screw Washer Nut 15. 16. 17. 18. 19. Rod End Linkage Bushing Washer E-Ring 0739-701 1. Place the shift lever in the R position; then remove the seat. NOTE: Steps 2-8 are for all models except the 700 EFI. For the 700 EFI, proceed to step 9. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the left-side splash panel. 3. Loosen shift rod end jam nut (A). FI010A 10. Turn the ignition switch to the ON position; then move the shift arm (3) until the Neutral icon (N) appears on the LCD. AF941A 4. Using two open-end wrenches, remove lock nut (B) securing the shift rod to the upper shift axle. Discard the lock nut. 11. Rotate the shift rod (4) until the shifter is directly aligned with the Neutral position on the shift gate. NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. 12. While holding the shift rod with an open-end wrench, tighten the shift rod jam nuts securely. 5. Push the upper shift axle down completely. 6. Rotate the shift rod end as necessary to align its threaded shaft with the hole in the upper shift axle. Secure with a new lock nut (B). Tighten securely. 7. Tighten jam nut (A) to secure the adjustment. 8. Install the left-side splash panel; then install the seat. 9. Loosen the front shift rod jam nut (1) (left-hand threads); then loosen the rear shift rod jam nut (2) (right-hand threads). 13. Shift the transmission into each of the remaining positions and verify that the appropriate icon is displayed for the selected gear shift position (H High, L - Low, and R - Reverse). NOTE: An E (Error) in the gear position icon indicates no signal or a poor ground wire connection in the circuit. Troubleshoot the harness connectors, gear shift position connector, gear shift position switch, and LCD connector. Frame/Welds/Racks The frame, welds, and racks should be checked periodically for damage, bends, cracks, deterioration, broken components, and missing components. If replacement or repair constitutes removal, see Section 8. Electrical Connections FI059A The electrical connections should be checked periodically for proper function. In case of an electrical failure, check fuses, connections (for tightness, corrosion, damage), and/or bulbs. If an electrical component needs to be tested for proper function, see Section 5. www.mymowerparts.com 2-19 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Remove the protective cap, install one end of a clear hose onto one FRONT bleeder screw, and direct the other end into a container; then while holding slight pressure on the brake lever, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake lever. Repeat this procedure until no air bubbles are present. Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake system, use the following procedure. 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the reservoir is not visible in the sight glass, add DOT 4 brake fluid. AF637D 738-420A PR377A AL681 2. Compress the brake lever/pedal several times to check for a firm brake. If the brake is not firm, the system must be bled. 3. To bleed the brake system, use the following procedure. A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid. B. Install and secure the cover; then slowly compress the brake lever several times. www.mymowerparts.com 2-20 NOTE: During the bleeding procedure, watch the reservoir sight glass very closely to make sure there is always a sufficient amount of brake fluid. When the sight glass changes from dark to light, refill the reservoir before the bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system. D. Repeat step C until the brake lever is firm. E. At this point, perform step B, C, and D on the other FRONT bleeder screw; then move to the REAR bleeder screw and follow the same procedure. 4. Carefully check the entire hydraulic brake system that all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION This hydraulic brake system is designed to use DOT 4 brake fluid only. If brake fluid must be added, care must be taken as brake fluid is very corrosive to painted surfaces. INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, the brake hoses must be replaced. PR237 CHECKING/REPLACING PADS C. Install the new brake pads. The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows. D. Secure the caliper to the knuckle and/or axle housing with the cap screws. Tighten to specifications. 1. Remove a front wheel. 2. Measure the thickness of each brake pad. 3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced. PR377B E. Install the wheel. Tighten to specifications. 5. Burnish the brake pads (see Burnishing Brake Pads in this section). Burnishing Brake Pads PR376B NOTE: The brake pads should be replaced as a set. 4. To replace the brake pads, use the following procedure. A. Remove the wheel. B. Remove the cap screws securing the caliper holder to the knuckle; then remove the pads. Brake pads (both hydraulic and auxiliary) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury. 1. Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop. www.mymowerparts.com 2. Accelerate to 30 mph; then compress brake lever or apply the auxiliary brake to decelerate to 0-5 mph. 2-21 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Repeat procedure on each brake system five times until brake pads are burnished. 4. Adjust the auxiliary brake (if necessary). 5. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed. Coolant (500/650 H1/700 EFI) The cooling system should be inspected daily for leakage and damage. Also, the coolant level should be checked periodically. When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system to the bottom of the stand pipe in the radiator neck. CD078 NOTE: Note the location of the main engine ground wire for installing purposes. 3. Remove the nut securing the movable drive face; then remove the face. Account for the spacer. ! CAUTION After operating the ATV for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary. Checking/Replacing V-Belt CC546 REMOVING 1. Remove the right-side footrest (see Section 8). 2. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Remove the cover. www.mymowerparts.com 2-22 CC547 4. Remove the V-belt. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC550 CC552 NOTE: At this point, the wedge can be removed from between the driven clutch faces. INSTALLING 1. Spread the faces of the driven clutch by pushing the inner face toward the engine while turning it counterclockwise; then when the faces are separated, insert a wedge (approximately 3/8 in. thick) between the faces. Release the inner face. 4. Rotate the V-belt and clutches until the V-belt is flush with the top of the driven clutch. 5. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to specifications (see Section 10). CC549 2. Place the V-belt into position on the driven clutch and over the front shaft. CD083 NOTE: Make sure the main engine ground wire is installed and secured in the proper location. 6. Secure the front fender to the footrest with the two cap screws. Tighten securely. 7. Install the right-side footrest (see Section 8). CC550 NOTE: The arrow on the V-belt should point forward. 3. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a nut. Tighten the nut to specifications (see Section 10). www.mymowerparts.com 2-23 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjusting Differential Lock Cable NOTE: The following procedure include the 400 TRV model. does not If the differential or differential lock system has been serviced, the differential lock cable should be checked and/or adjusted for proper free-play. To adjust the cable, use the following procedure. 1. With the differential lock selector in the UNLOCK position, slide the rubber boot (A) off the adjuster; then loosen the jam nut (B). Turn the adjuster (C) to achieve 6.35 mm (0.250 in.) of free-play measured at the end of the differential lock lever. CD560A 2. Select the 2WD position on the front drive selector switch; then turn the ignition switch to the ON position and select the LOCK position on the differential lock selector. The front drive actuator should operate engaging four-wheel drive. NOTE: It may be necessary to turn the handlebar or rock the ATV forward and backward to align the differential lock splines and allow engagement. 3. Return the differential lock selector to the UNLOCK position and listen for the front drive actuator to operate. 4. Turn the ignition switch to the OFF position. Tighten the jam nut securely; then install the boot on the adjuster. www.mymowerparts.com 2-24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Exhaust Chart NOTE: Use this chart in conjunction with the procedure found in Valve/Tappet Clearance (700 EFI) in this section. 2 www.mymowerparts.com ATV2152A 2-25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Intake Chart www.mymowerparts.com 2-26 NOTE: Use this chart in conjunction with the procedure found in Valve/Tappet Clearance (700 EFI) in this section. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION 3 TABLE OF CONTENTS Engine/Transmission ............................................... 3-2 Specifications (400 - Automatic Transmission)........ 3-3 Specifications (400 - Manual Transmission)............ 3-4 Specifications (500 - Automatic Transmission)........ 3-6 Specifications (500 - Manual Transmission)............ 3-7 Specifications (650 H1) ........................................... 3-9 Specifications (700 EFI) ........................................ 3-10 400 (Manual Transmission) Table of Contents ................................................. 3-11 400 (Automatic Transmission) Table of Contents ................................................. 3-76 500 (Automatic Transmission)/650 H1 Table of Contents ............................................... 3-130 500 (Manual Transmission) Table of Contents ............................................... 3-185 700 EFI Table of Contents................................... 3-256 www.mymowerparts.com 3-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission This section has been organized into sub-sections which show a progression for the complete servicing of the Arctic Cat ATV engine/transmission. To service the center crankcase halves, the engine/transmission must be removed from the frame. To service top-side, left-side, and right-side components, the engine/transmission does not have to be removed from the frame. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 10. www.mymowerparts.com 3-2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* (400 - Automatic Transmission) VALVES AND GUIDES CYLINDER, PISTON, AND RINGS Valve Face Diameter (intake) 30.6 mm (1.20 in.) (exhaust) 27.0 mm (1.06 in.) Piston Skirt/Cylinder Clearance Valve/Tappet Clearance (cold engine) (intake) 0.05-0.10 mm (0.002-0.004 in.) (exhaust) 0.22-0.27 mm (0.009-0.011 in.) Cylinder Bore 82.000-82.015 mm (3.2283-3.2289 in.) Piston Diameter 15 mm (0.6 in.) from Skirt End 81.930-81.945 mm (3.2256-3.2262 in.) Valve Guide/Stem Clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in.) (exhaust) 0.030-0.057 mm (0.0012-0.0022 in.) Valve Guide/Valve Stem Deflection (wobble deflection) (max) 0.35 mm (0.014 in.) Valve Guide Inside Diameter 5.000-5.012 mm (0.1969-0.1973 in.) Valve Stem Outside Diameter (intake) 4.975-4.990 mm (0.1959-0.1965 in.) (exhaust) 4.955-4.970 mm (0.1951-0.1957 in.) Valve Stem Runout (max) 0.05 mm (0.002 in.) Valve Head Thickness (min) 0.5 mm (0.02 in.) Valve Stem End Length (min) 2.3 mm (0.09 in.) Valve Face/Seat Width Piston Ring Free End Gap (min) (intake) 45° (exhaust) 45° Valve Face Radial Runout Bore x Stroke (min) 38.8 mm (1.53 in.) Valve Spring Tension @ 32.5 mm (1.28 in.) Cylinder Trueness (max) 0.05 mm (0.002 in.) Piston Ring End Gap - Installed (outer) 18.6-21.4 kg (41-47 lb) Cam Lobe Height (min) (intake) 32.830 mm (exhaust) (1.293 in.) 32.830 mm (1.293 in.) Camshaft Journal Oil Clearance (max) 0.15 mm (0.0059 in.) (right & center) 22.012-22.025 mm (0.8666-0.8671 in.) (left) 17.512-17.525 mm (0.6894-0.6900 in.) (right & center) 21.959-21.980 mm (0.8645-0.8654 in.) (left) 17.466-17.484 mm (0.6876-0.6883 in.) Camshaft Runout (max) 0.10 mm (0.004 in.) Rocker Arm Inside Diameter 12.000-12.018 mm (0.472-0.473 in.) Rocker Arm Shaft Outside Diameter 11.973-11.984 mm (0.4714-0.4718 in.) Cylinder Head Distortion (max) 0.05 mm (0.002 in.) Cylinder Head Cover Distortion (max) 0.05 mm (0.002 in.) 0.33-0.61 mm (0.013-0.024 in.) 3 Piston Ring to Groove Clearance (max) (1st) 0.180 mm (0.0071 in.) (2nd) 0.150 mm (0.0059 in.) Piston Ring Groove Width (1st) 1.01-1.03 mm (0.0398-0.0406 in.) (2nd) 1.01-1.03 mm (0.0398-0.0406 in.) (oil) 2.01-2.03 mm (0.0791-0.0799 in.) Piston Ring Thickness (1st) 0.97-0.99 mm (0.0381-0.0389 in.) (2nd) 0.97-0.99 mm (0.0381-0.0389 in.) Piston Pin Bore (max) 20.03 mm (0.789 in.) Piston Pin Outside Diameter (min) 19.98 mm (0.787 in.) CRANKSHAFT CAMSHAFT AND CYLINDER HEAD Camshaft Journal Outside Diameter 82 x 71.2 mm (3.29 x 2.80 in.) (max) 0.03 mm (0.001 in.) Valve Spring Free Length Camshaft Journal Holder Inside (1st Ring) 8.9 mm (0.3504 in.) (2nd Ring) 8.3 mm (0.3268 in.) 0.9-1.1 mm (0.035-0.043 in.) Valve Seat Angle 0.060-0.073 mm (0.0024-0.0029 in.) Connecting Rod (small end inside diameter) (max) 20.04 mm (0.7889 in.) Connecting Rod (big end side-to-side) 0.10-0.55 mm (0.004-0.022 in.) Connecting Rod (big end width) 21.95-22.00 mm (0.8642-0.8661 in.) Connecting Rod (small end deflection) Crankshaft (web-to-web) Crankshaft Runout Oil Pressure at 60°C (140°F) @ 3000 RPM (max) 3 mm (0.12 in.) 59.9-60.1 mm (2.358-2.366 in.) (max) 0.08 mm (0.003 in.) (above) 1.1 kg/cm² (16 psi) (below) 1.5 kg/cm² (21 psi) Cooling Fan Thermo-Switch Operating Temperature (off J on) 120°C (248°F) (on J off) 110°C (230°F) Engine Oil Thermo-Switch Operating Temperature (off J on) 160°C (320°F) (on J off) 140°C (284°F) * Specifications subject to change without notice. www.mymowerparts.com 3-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* (400 - Manual Transmission) VALVES AND GUIDES CYLINDER, PISTON, AND RINGS Valve Face Diameter (intake) 30.6 mm (1.20 in.) (exhaust) 27.0 mm (1.06 in.) Piston Skirt/Cylinder Clearance Valve/Tappet Clearance (cold engine) (intake) 0.05-0.10 mm (0.002-0.004 in.) (exhaust) 0.22-0.27 mm (0.009-0.011 in.) Cylinder Bore 82.000-82.015 mm (3.2283-3.2289 in.) Piston Diameter 15 mm (0.6 in.) from Skirt End 81.930-81.945 mm (3.2256-3.2262 in.) Valve Guide/Stem Clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in.) (exhaust) 0.030-0.057 mm (0.0012-0.0022 in.) Valve Guide/Valve Stem Deflection (wobble deflection) (max) 0.35 mm (0.014 in.) Valve Guide Inside Diameter 5.000-5.012 mm (0.1969-0.1973 in.) Valve Stem Outside Diameter (intake) 4.975-4.990 mm (0.1959-0.1965 in.) (exhaust) 4.955-4.970 mm (0.1951-0.1957 in.) Valve Stem Runout (max) 0.05 mm (0.002 in.) Valve Head Thickness (min) 0.5 mm (0.02 in.) Valve Stem End Length (min) 2.3 mm (0.09 in.) Valve Face/Seat Width (1st Ring) 8.9 mm (0.3504 in.) (2nd Ring) 8.3 mm (0.3268 in.) Bore x Stroke 82 x 71.2 mm (3.29 x 2.80 in.) Cylinder Trueness (max) 0.05 mm (0.002 in.) Piston Ring End Gap - Installed (intake) 45° (exhaust) 45° Valve Face Radial Runout (max) 0.03 mm (0.001 in.) Valve Spring Free Length (min) 38.8 mm (1.53 in.) Valve Spring Tension @ 32.5 mm (1.28 in.) (outer) 18.6-21.4 kg (41-47 lb) CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (intake) 32.830 mm (1.293 in.) (exhaust) 32.830 mm (1.293 in.) Camshaft Journal Oil Clearance (max) 0.15 mm (0.0059 in.) Camshaft Journal Holder (right & center) 22.012-22.025 mm Inside (0.8666-0.8671 in.) (left) 17.512-17.525 mm (0.6894-0.6900 in.) (right & center) 21.959-21.980 mm (0.8645-0.8654 in.) (left) 17.466-17.484 mm (0.6876-0.6883 in.) Camshaft Runout (max) 0.10 mm (0.004 in.) 0.33-0.61 mm (0.013-0.024 in.) Piston Ring to Groove Clearance (max) (1st) 0.180 mm (0.0071 in.) (2nd) 0.150 mm (0.0059 in.) Piston Ring Groove Width (1st) 1.01-1.03 mm (0.0398-0.0406 in.) (2nd) 1.01-1.03 mm (0.0398-0.0406 in.) (oil) 2.01-2.03 mm (0.0791-0.0799 in.) Piston Ring Thickness (1st) 0.97-0.99 mm (0.0381-0.0389 in.) (2nd) 0.97-0.99 mm (0.0381-0.0389 in.) Piston Pin Bore (max) 20.03 mm (0.789 in.) Piston Pin Outside Diameter (min) 19.98 mm (0.787 in.) 0.9-1.1 mm (0.035-0.043 in.) Valve Seat Angle Camshaft Journal Outside Diameter Piston Ring Free End Gap (min) 0.060-0.073 mm (0.0024-0.0029 in.) CRANKSHAFT Connecting Rod (small end inside diameter) (max) 20.04 mm (0.7889 in.) Connecting Rod (big end side-to-side) 0.10-0.55 mm (0.004-0.022 in.) Connecting Rod (big end width) 21.95-22.00 mm (0.8642-0.8661 in.) Connecting Rod (small end deflection) Crankshaft (web-to-web) Crankshaft Runout (max) Oil Pressure at 60°C (140°F) @ 3000 RPM (max) 3 mm (0.12 in.) 59.9-60.1 mm (2.358-2.366 in.) 0.08 mm (0.003 in.) (above) 0.6 kg/cm² (9 psi) (below) 1.0 kg/cm² (14 psi) Rocker Arm Inside Diameter 12.000-12.018 mm (0.472-0.473 in.) Cooling Fan Thermo-Switch Operating Temperature (off J on) 120°C (248°F) (on J off) 110°C (230°F) Rocker Arm Shaft Outside Diameter 11.973-11.984 mm (0.4714-0.4718 in.) Engine Oil Thermo-Switch Operating Temperature (off J on) 160°C (320°F) (on J off) 140°C (284°F) Cylinder Head Distortion (max) 0.05 mm (0.002 in.) Cylinder Head Cover Distortion (max) 0.05 mm (0.002 in.) www.mymowerparts.com 3-4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLUTCH Clutch Release Screw 1/8 turn back Drive Plate (fiber) Thickness (min) 2.62 mm (0.103 in.) Drive Plate (fiber) Tab 13.25-13.95 mm (0.52-0.55 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.) Clutch Spring Length (min) 33.7 mm (1.33 in.) Clutch Wheel Inside Diameter 140.0-140.2 mm (5.511-5.520 in.) Starter Clutch Shoe No groove at any part Clutch Engagement RPM 1700 ± 200 Clutch Lock-Up RPM 3400 - 4000 Primary Reduction Ratio 2.392 (67/28) Secondary Reduction Ratio 1.133 (17/15) Final Reduction Ratio (front) 3.6 (36/10) (rear) 3.6 (36/10) Secondary Transmission Reduction Ratio (low) 2.435 (35/13 x 19/21) (high) 1.296 (35/27) Gear Ratios (1st) (2nd) (3rd) (4th) (5th) (reverse) Engine Fork to Groove (side clearance) 3 3.083 (37/12) 1.933 (29/15) 1.388 (25/18) 1.095 (23/21) 0.913 (21/23) 2.833 (34/12) 0.1-0.3 mm (0.004-0.012 in.) Secondary Transmission Fork to Groove 0.1-0.3 mm (side clearance) (0.004-0.012 in.) Reverse Fork to Groove (side clearance) 0.1-0.3 mm (0.004-0.012 in.) Shift Fork Groove Width (#1 and #2) 4.5-4.6 mm (0.177-0.181 in.) (secondary transmission) 5.45-5.55 mm (0.215-0.219 in.) (reverse) 4.0-4.1 mm (0.157-0.161 in.) (#1 and #2) 4.3-4.4 mm (0.169-0.173 in.) (secondary transmission) 5.3-5.4 mm (0.209-0.213 in.) (reverse) 3.8-3.9 mm (0.150-0.154 in.) Shift Fork Thickness * Specifications subject to change without notice. www.mymowerparts.com 3-5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* (500 - Automatic Transmission) CYLINDER, PISTON, AND RINGS VALVES AND GUIDES Valve Face Diameter (intake) 30.6 mm (1.20 in.) (exhaust) 27.0 mm (1.06 in.) Piston Skirt/Cylinder Clearance Valve/Tappet Clearance (cold engine) (intake) 0.05-0.10 mm (0.002-0.004 in.) (exhaust) 0.17-0.22 mm (0.007-0.009 in.) Cylinder Bore Valve Guide/Stem Clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in.) (exhaust) 0.030-0.057 mm (0.0012-0.0022 in.) Valve Guide/Valve Stem Deflection (wobble deflection) (max) 0.35 mm (0.014 in.) Valve Guide Inside Diameter 5.000-5.012 mm (0.1969-0.1973 in.) Valve Stem Outside Diameter (intake) 4.975-4.990 mm (0.1959-0.1965 in.) (exhaust) 4.955-4.970 mm (0.1951-0.1957 in.) Valve Stem Runout (max) 0.05 mm (0.002 in.) Valve Head Thickness (min) 0.5 mm (0.02 in.) Valve Stem End Length (min) 2.3 mm (0.09 in.) Valve Face/Seat Width (intake) 45° (exhaust) 45° Valve Face Radial Runout Piston Ring Free End Gap (min) (min) 38.8 mm (1.53 in.) Valve Spring Tension @ 31.5 mm (1.24 in.) (outer) 18.6-21.4 kg (41-47 lb) (intake) 33.13 mm (1.304 in.) (exhaust) 33.20 mm (1.307 in.) Camshaft Journal Oil Clearance (max) 0.15 mm (0.0059 in.) Camshaft Journal Holder (right & center) 22.012-22.025 mm Inside (0.8666-0.8671 in.) (left) 17.512-17.525 mm (0.6894-0.6900 in.) Camshaft Journal Outside Diameter 87.5 x 82 mm (3.40 x 3.22 in.) Cylinder Trueness (max) 0.05 mm (0.002 in.) Piston Ring End Gap - Installed (right & center) 21.959-21.980 mm (0.8645-0.8654 in.) (left) 17.466-17.484 mm (0.6876-0.6883 in.) Camshaft Runout (max) 0.10 mm (0.004 in.) 0.35-0.63 mm (0.014-0.025 in.) Piston Ring to Groove Clearance (max) (1st) 0.180 mm (0.0071 in.) (2nd) 0.150 mm (0.0059 in.) Piston Ring Groove Width (1st) 1.01-1.03 mm (0.0398-0.0406 in.) (2nd) 1.21-1.23 mm (0.0476-0.0484 in.) (oil) 2.51-2.53 mm (0.0988-0.0996 in.) Piston Ring Thickness (1st) 0.97-0.99 mm (0.0382-0.0389 in.) (2nd) 1.17-1.19 mm (0.046-0.047 in.) Piston Pin Bore (max) 23.03 mm (0.907 in.) Piston Pin Outside Diameter (min) 22.98 mm (0.905 in.) CRANKSHAFT CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (1st Ring) 9.0 mm (0.35 in.) (2nd Ring) 9.5 mm (0.37 in.) Bore x Stroke (max) 0.03 mm (0.001 in.) Valve Spring Free Length 87.500-87.515 mm (3.4448-3.4454 in.) Piston Diameter 15 mm (0.6 in.) from Skirt 87.465-87.480 mm End (3.4435-3.4440 in.) 0.9-1.1 mm (0.035-0.043 in.) Valve Seat Angle 0.030-0.040 mm (0.0011-0.0015 in.) Connecting Rod (small end inside diameter) (max) 23.04 mm (0.9070 in.) Connecting Rod (big end side-to-side) 0.10-0.65 mm (0.0039-0.0256 in.) Connecting Rod (big end width) 24.95-25.00 mm (0.9822-0.9842 in.) Connecting Rod (small end deflection) Crankshaft (web-to-web) Crankshaft Runout Oil Pressure at 60°C (140°F) @ 3000 RPM (max) 3 mm (0.12 in.) 70.9-70.1 mm (2.796-2.804in.) (max) 0.08 mm (0.003 in.) (above) 1.3 kg/cm² (18 psi) (below) 1.7 kg/cm² (24 psi) (off J on) 88°C (190°F) (on J off) 82°C (180°F) (min) Rocker Arm Inside Diameter 12.000-12.018 mm (0.472-0.473 in.) Cooling Fan Thermo-Switch Operating Temperature Rocker Arm Shaft Outside Diameter 11.973-11.984 mm (0.4714-0.4718 in.) Engine Coolant Thermo-Switch (off J on) 115°C (239°F) Operating Temperature (on J off) 108°C (226°F) (approx) Cylinder Head Distortion (max) 0.05 mm (0.002 in.) Cylinder Head Cover Distortion (max) 0.05 mm (0.002 in.) www.mymowerparts.com 3-6 * Specifications subject to change without notice. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* (500 - Manual Transmission) CYLINDER, PISTON, AND RINGS VALVES AND GUIDES Valve Face Diameter (intake) 30.6 mm (1.20 in.) (exhaust) 27.0 mm (1.06 in.) Piston Skirt/Cylinder Clearance Valve/Tappet Clearance (cold engine) (intake) 0.05-0.10 mm (0.002-0.004 in.) (exhaust) 0.17-0.22 mm (0.007-0.009 in.) Cylinder Bore 87.500-87.515 mm (3.4448-3.4454 in.) Piston Diameter 15 mm (0.6 in.) from Skirt End 87.465-87.480 mm (3.4435-3.4440 in.) Valve Guide/ Stem Clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in.) (exhaust) 0.030-0.057 mm (0.0012-0.0022 in.) Valve Guide/Valve Stem Deflection (wobble deflection) (max) 0.35 mm (0.014 in.) Valve Guide Inside Diameter Valve Stem Outside Diameter 5.000-5.012 mm (0.1969-0.1973 in.) (intake) 4.975-4.990 mm (0.1959-0.1965 in.) (exhaust) 4.955-4.970 mm (0.1951-0.1957 in.) Valve Stem Runout (max) 0.05 mm (0.002 in.) Valve Head Thickness (min) 0.5 mm (0.02 in.) Valve Stem End Length (min) 1.7 mm (0.067 in.) Valve Face/Seat Width Valve Seat Angle Piston Ring Free End Gap (min) Valve Face Radial Runout Bore x Stroke 87.5 x 82 mm (3.40 x 3.22 in.) Cylinder Trueness (max) 0.05 mm (0.002 in.) Piston Ring End Gap Installed 0.35-0.63 mm (0.014-0.025 in.) (min) 38.8 mm (1.53 in.) Valve Spring Tension @ 31.5 mm (1.24 in.) (outer) 18.2-21.0 kg (40.1-46.3 lb) (1st) 0.180 mm (0.0071 in.) (2nd) 0.150 mm (0.0059 in.) Piston Ring Groove Width (1st) 1.01-1.03 mm (0.0398-0.0406 in.) (2nd) 1.21-1.23 mm (0.0476-0.0484 in.) (oil) 2.51-2.53 mm (0.0988-0.0996 in.) Piston Ring Thickness (1st) 0.97-0.99 mm (0.0382-0.0389 in.) (2nd) 1.17-1.19 mm (0.046-0.047 in.) Piston Pin Bore (max) 23.03 mm (0.907 in.) Piston Pin Outside Diameter (min) 22.98 mm (0.905 in.) CRANKSHAFT CAMSHAFT AND CYLINDER HEAD (intake) 33.13 mm (1.304 in.) (exhaust) 33.20 mm (1.307 in.) Camshaft Journal Oil Clearance (max) 0.15 mm (0.0059 in.) Camshaft Journal Holder Inside (right & center) 22.012-22.025 mm (0.8666-0.8671 in.) (left) 17.512-17.525 mm (0.6894-0.6900 in.) Camshaft Journal Outside Diameter (right & center) 21.959-21.980 mm (0.8645-0.8654 in.) (left) 17.466-17.484 mm (0.6876-0.6883 in.) Camshaft Runout (max) 0.10 mm (0.004 in.) Rocker Arm Inside Diameter 12.000-12.018 mm (0.472-0.473 in.) Rocker Arm Shaft Outside Diameter 11.973-11.984 mm (0.4714-0.4718 in.) Cylinder Head Distortion (max) 0.05 mm (0.002 in.) Cylinder Head Cover Distortion (max) 0.05 mm (0.002 in.) 3 Piston Ring to Groove Clearance (max) (max) 0.03 mm (0.001 in.) Valve Spring Free Length Cam Lobe Height (min) (1st Ring) 9.0 mm (0.35 in.) (2nd Ring) 9.5 mm (0.37 in.) 0.9-1.1 mm (0.035-0.043 in.) (intake) 45° (exhaust) 45° 0.030-0.040 mm (0.0011-0.0015 in.) Connecting Rod (small end inside diameter) (max) 23.04 mm (0.9070 in.) Connecting Rod (big end side-to-side) 0.10-0.65 mm (0.0039-0.0256 in.) Connecting Rod (big end width) 24.95-25.00 mm (0.9822-0.9842 in.) Connecting Rod (small end deflection) (max) 3 mm (0.12 in.) Crankshaft (web-to-web) 70.9-70.1 mm (2.796-2.804in.) Crankshaft Runout (max) 0.08 mm (0.003 in.) Oil Pressure at 60°C (140°F) @ 3000 RPM (above) 1.2 kg/cm² (17 psi) (below) 1.6 kg/cm² (23 psi) www.mymowerparts.com 3-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLUTCH Clutch Release Screw 1/4-1/2 turn back Drive Plate (fiber) Thickness (min) 2.82 mm (0.1110 in.) Drive Plate (fiber) Tab (min) 2.9 mm (0.507 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.) Clutch Spring Length (min) 35.6 mm (1.40 in.) Clutch Wheel Inside Diameter 140.0-140.2 mm (5.511-5.520 in.) Starter Clutch Shoe No groove at any part Clutch Engagement RPM 1700 ± 200 Clutch Lock-Up RPM 3700 ± 300 Primary Reduction Ratio 2.032 (63/31) Secondary Reduction Ratio 1.133 (17/15) Final Reduction Ratio (front) 3.6 (36/10) (rear) 3.6 (36/10) Secondary Transmission Reduction Ratio (low) 2.419 (22/23 x 27/17 x 43/27) (high) 1.592 (43/27) Gear Ratios (1st) (2nd) (3rd) (4th) (5th) (reverse) Engine Fork to Groove (side clearance) 3.09 (34/11) 1.75 (28/16) 1.2 (24/20) 0.875 (21/24) 0.724 (21/29) 2.636 (24/11 x 29/24) 0.1-0.3 mm (0.004-0.012 in.) Secondary Transmission Fork to Groove 0.1-0.3 mm (side clearance) (0.004-0.012 in.) Reverse Fork to Groove (side clearance) 0.1-0.3 mm (0.004-0.012 in.) Shift Fork Groove Width (#1 and #2) 5.5-5.6 mm (0.217-0.220 in.) (secondary transmission) 5.5-5.6 mm (0.217-0.220 in.) (reverse) 5.0-5.1 mm (0.197-0.201 in.) Shift Fork Thickness (#1 and #2) 5.3-5.4 mm (0.209-0.213 in.) (secondary transmission) 5.3-5.4 mm (0.209-0.213 in.) (reverse) 4.8-4.9 mm (0.189-0.193 in.) Thermostat Valve Opening Temperature 73.5-76.5°C (164-170°F) Thermostat Valve Lift Over 3 mm (0.12 in.) @ 90°C (194°F) Cooling Fan Thermo-Switch Operating Temperature (off J on) 88°C (190°F) (on J off) 82°C (180°F) (min) Engine Coolant Thermo-Switch Operating Temperature (off J on) 115°C (239°F) (on J off) 108°C (226°F) (approx) * Specifications subject to change without notice. www.mymowerparts.com 3-8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* (650 H1) VALVES AND GUIDES Valve Face Diameter (intake) 31.6 mm (1.24 in.) (exhaust) 27.9 mm (1.10 in.) Valve/Tappet Clearance (cold engine) (intake) 0.1016 mm (0.004 in.) (exhaust) 0.1524 mm (0.006 in.) Valve Guide/Stem Clearance (intake) 0.013 mm (0.0005 in.) (exhaust) 0.013 mm (0.0005 in.) Valve Guide/Valve Stem Deflection (wobble method) (max) 0.35 mm (0.014 in.) CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance 0.045 mm (0.0018 in.) Cylinder Bore 98 mm (3.858 in.) Piston Diameter 15 mm (0.6 in.) from Skirt End 97.948-97.962 mm (3.856-3.857 in.) Piston Ring Free End Gap (1st ring) 12.5 mm (0.492 in.) (2nd ring) 12.5 mm (0.492 in.) Bore x Stroke Valve Guide Inside Diameter 5.000-5.012 mm (0.1969-0.1973 in.) Valve Stem Outside Diameter (intake) 4.972-4.987 mm (0.1957-0.1963 in.) (exhaust) 4.972-4.987 mm (0.1957-0.1963 in.) Valve Stem Runout (max) 0.1 mm (0.0039 in.) Valve Head Thickness (min) 2.3 mm (0.0906 in.) Valve Stem End Length 97.9 x 85 mm (3.86 x 3.35 in.) Cylinder Trueness (max) 0.01 mm (0.004 in.) Piston Ring End Gap - Installed Piston Ring to Groove Clearance (max) (1st) 0.03 mm (0.0012 in.) (2nd) 0.03 mm (0.0012 in.) Piston Ring Groove Width (1st) 1.202-1.204 mm (0.0473-0.0474 in.) (2nd) 1.202-1.204 mm (0.0473-0.0474 in.) (oil) 2.01-2.03 mm (0.0791-0.0799 in.) Piston Ring Thickness (1st) 1.970-1.990 mm (0.0776-0.0783 in.) (2nd) 1.970-1.990 mm (0.0776-0.0783 in.) (min) 3.97 mm (0.156 in.) Valve Face/Seat Width (intake) 2.25 mm (0.0886 in.) (exhaust) 2.60 mm (0.1024 in.) Valve Seat Angle (intake) 45° 15’-45° 30’ (exhaust) 45° 15’-45° 30’ 0.36 mm (0.014 in.) Valve Face Radial Runout (max) 0.2 mm (0.0079 in.) Piston Pin Bore (max) 23.0 mm (0.9055 in.) Valve Spring Free Length (min) 38.7 mm (1.524 in.) Piston Pin Outside Diameter (min) 22.99 mm (0.9051 in.) Valve Spring Tension @ 31.5 mm (1.24 in.) (outer) 19.0 kg (42 lb) CRANKSHAFT CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (intake) 13.97 mm (0.55 in.) (exhaust) 13.97 mm (0.55 in.) Camshaft Journal Oil Clearance (max) 0.04 mm (0.0016 in.) Connecting Rod (small end inside diameter) (max) 23.021 mm (0.9063 in.) Connecting Rod (big end side-to-side) 0.6 mm (0.024 in.) Connecting Rod (big end width) 25 mm (0.9843 in.) Camshaft Journal Holder Inside Diameter (right & center) 21.98-22.04 mm (0.8654-0.8677 in.) (left) 17.48-17.53 mm (0.6882-0.6902 in.) Connecting Rod @ 150 mm (5.9 in.) (small end deflection) (max) 0.3 mm (0.0118 in.) Camshaft Journal Outside Diameter (right & center) 21.96-21.98 mm (0.8646-0.8654 in.) (left) 17.47-17.48 mm (0.6878-0.6882 in.) Crankshaft Runout Camshaft Runout (max) 0.05 mm (0.002 in.) Rocker Arm Inside Diameter 12.000-12.018 mm (0.4724-0.4731 in.) Rocker Arm Shaft Outside Diameter 11.97-11.98 mm (0.4713-0.4717 in.) Cylinder Head Distortion (max) 0.05 mm (0.002 in.) Cylinder Head Cover Distortion 3 Crankshaft (web-to-web) Oil Pressure at 60°C (140°F) @3000 RPM 71 mm (2.79 in.) (max) 0.03 mm (0.0012 in.) 1.40-2.46 kg/cm² (20-35 psi) Cooling Fan Thermo-Switch Operating Temperature (offJon) 90°C (194°F) (onJoff) 75°C (167°F) Engine Coolant Thermo-Switch Operating Temperature (offJon) 115°C (239°F) (onJoff) 108°C (226°F) (approx) * Specifications subject to change without notice. (max) 0.05 mm (0.002 in.) www.mymowerparts.com 3-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* (700 EFI) VALVES AND GUIDES CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance (max) 0.120 mm (0.0047 in.) Valve Face Diameter (intake) 36.0 mm (1.42 in.) (exhaust) 33.0 mm (1.30 in.) Cylinder Bore 98 mm (3.858 in.) Valve/Tappet Clearance (cold engine) (intake) 0.10-0.20 mm (0.004-0.008 in.) (exhaust) 0.20-0.30 mm (0.008-0.012 in.) Piston Diameter 15 mm (0.6 in.) from Skirt End 102.000-102.015 mm (4.0157-4.0163 in.) Valve Guide/Stem Clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in.) (exhaust) 0.030-0.057 mm (0.0012-0.0022 in.) Bore x Stroke Valve Stem Deflection (wobble method) (max) 0.35 mm (0.014 in.) 5.500-5.512 mm (0.2165-0.2170 in.) Valve Stem Outside Diameter (intake) 5.475-5.490 mm (0.2156-0.2161 in.) (exhaust) 5.455-5.470 mm (0.2148-0.2154 in.) Valve Stem Runout (max) 0.05 mm (0.002 in.) Valve Head Thickness (min) 0.5 mm (0.02 in.) (intake/exhaust) 0.9-1.1 mm (0.035-0.043 in.) Valve Face Radial Runout (max) 0.03 mm (0.001 in.) Valve Spring Free Length (min) 46.1 mm (1.81 in.) Valve Spring Tension @ 36.35 mm (1.43 in.) Camshaft Journal Oil Clearance 102 x 85 mm (4.016 x 3.350 in.) Cylinder Trueness (max) 0.05 mm (0.002 in.) 18.6-21.4 kg (41.0-47.2 lb) Piston Ring to Groove Clearance (max) (1st) 0.180 mm (0.0071 in.) (2nd) 0.150 mm (0.0059 in.) Piston Ring Groove Width (1st) 0.83-0.85 mm (0.0327-0.0335 in.) 1.30-1.32 mm (0.0512-0.0520 in.) (2nd) 1.010-1.030 mm (0.0398-0.0406 in.) (oil) 2.01-2.03 mm (0.0791-0.0799 in.) Piston Ring Thickness (1st) 1.08-1.10 mm (0.0425-0.0433 in.) (2nd) 0.970-0.990 mm (0.0382-0.0390 in.) Piston Pin Bore (max) 23.030 mm (0.9067 in.) Piston Pin Outside Diameter (min) 22.98 mm (0.9047 in.) CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (1st ring) 8.3 mm (0.33 in.) (2nd ring) 11.4 mm (0.45 in.) Piston Ring End Gap - Installed (min) 0.10 mm (0.004 in.) Valve Guide Inside Diameter Valve Face/ Seat Width Piston Ring Free End Gap (min) (intake) 36.03 mm (1.4185 in.) (exhaust) 35.00 mm (1.3780 in.) (max) 0.150 mm (0.0059 in.) Camshaft Journal Holder Inside Diameter 22.012-22.025 mm (0.8666-0.8671 in.) Camshaft Journal Outside Diameter 21.972-21.993 mm (0.8650-0.8659 in.) Camshaft Runout (max) 0.10 mm (0.004 in.) Cylinder Head Distortion (max) 0.05 mm (0.002 in.) CRANKSHAFT Connecting Rod (small end inside diameter) (max) 23.040 mm (0.9071 in.) Connecting Rod (big end side-to-side) (max) 1.0 mm (0.004 in.) Connecting Rod (big end width) 25 mm (0.9843 in.) Connecting Rod @ 150 mm (5.9 in.) (small end deflection) (max) 0.3 mm (0.0118 in.) Crankshaft (web-to-web) Crankshaft Runout Oil Pressure at 60°C (140°F) @3000 RPM Cooling Fan Thermo-Switch Operating Temperature 72.9-73.1 mm (2.87-2.88 in.) (max) 0.08 mm (0.003 in.) 1.40-1.80 kg/cm² (20-26 psi) (offJon) 93°C (199°F) (onJoff) 87°C (189°F) * Specifications subject to change without notice. www.mymowerparts.com 3-10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (400 - Manual Transmission) 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery vent hose; then remove the battery. ! CAUTION Removing Engine/Transmission............................ 3-11 Top-Side Components........................................... 3-14 Removing Top-Side Components ......................... 3-14 Left-Side Components .......................................... 3-18 Removing Left-Side Components ......................... 3-18 Right-Side Components ........................................ 3-22 Removing Right-Side Components....................... 3-22 Center Crankcase Components............................ 3-26 Separating Crankcase Halves............................... 3-26 Disassembling Crankcase Half ............................. 3-27 Servicing Components.......................................... 3-29 Assembling Crankcase Half .................................. 3-56 Joining Crankcase Halves..................................... 3-58 Installing Right-Side Components......................... 3-59 Installing Left-Side Components ........................... 3-62 Installing Top-Side Components ........................... 3-66 Installing Engine/Transmission.............................. 3-72 Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 3. Remove the front and rear racks (see Section 8). 4. Remove the storage compartment and the steering post access panel (see Section 8). 5. Drain the oil transmission. from beneath the engine/ 3 Removing Engine/ Transmission ATV-0109 Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT 6. Remove the front and rear fender panels (see Section 8). 7. Disconnect the fuel hose (1), carburetor vent hose (2), and the fuel pump vacuum hose (3) from the carburetor. If the technician’s objective is to service/replace left-side cover oil seals (3), front output joint oil seal (1), rear output joint oil seal (1), and/or the oil strainer (from beneath the engine/ transmission), the engine/transmission does not have to be removed from the frame. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 1. Remove the seat. CF178A 8. Disconnect the crankcase vent hose from the air cleaner housing. Remove the clamp securing the air intake hose to the carburetor; then remove the housing. NOTE: The air cleaner intake duct must be removed prior to removing the air cleaner housing. www.mymowerparts.com 9. Remove the exhaust springs at the juncture in front of the muffler; then slide the muffler rearward off the mounting lugs. 3-11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF138A CC935 10. Remove the exhaust pipe and account for the exhaust seal. 13. Disconnect the speed sensor lead from the wiring harness. 11. Remove the pinch screw and lock nut securing the gear shift lever; then remove the gear shift lever from the shaft on the engine. CF172A CD003 14. Remove the four cap screws securing the rear output joint to the transmission and push the shaft rearward as far as possible. CC934 CC119D 12. Remove the E-clip securing the reverse/high/low shift linkage; then remove the linkage. Account for the bushing and washer. 15. Detach the carburetor from the intake boot; then secure the carburetor assembly away from the engine. www.mymowerparts.com 3-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC120D AR604D NOTE: Use cable ties or tape to secure the carburetor assembly above the handlebar to keep it from interfering with the removal procedure. 19. Disconnect the following electrical components: voltage regulator, CDI, indicator lights, and the two wire leads for the oil temperature sensors. 16. Remove the clamps securing the two oil cooler hoses to the engine; then disconnect the hoses. 3 CF165 CC937 NOTE: After disconnecting the oil cooler hoses, plug them to prevent leakage from the cooler. 17. Disconnect the high tension lead from the spark plug. At the ignition coil, remove the cap screw, nut, and the two wire leads; then remove the coil. 18. Disconnect the battery ground (negative) cable from the crankcase cover; then disconnect the positive cable from the starter motor. CF164A 20. Loosen the clamp on the crankcase breather vent hose; then disconnect the hose and remove it. 21. Remove the engine/transmission fasteners in the following sequence: mounting A. Lower front: One cap screw, nut, spacer, and washer. AR600D www.mymowerparts.com 3-13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. CF175 B. Lower rear: One cap screw and nut with flat washer. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to removed from the frame for this procedure. Removing Top-Side Components A. Valve Cover B. Cylinder Head CF176 22. By sliding the rear of the engine out first, remove the engine/transmission from the left side of the frame. NOTE: Remove the spark plug and timing inspection plug; then using the recoil starter, rotate the crankshaft to top-dead-center of the compression stroke. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. 1. Remove the cap screws securing the two tappet covers. Remove the two tappet covers. Account for the O-rings. CC940 MD1264 NOTE: Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated. www.mymowerparts.com 3-14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the cylinder head plug; then remove the plug. Note the location of two alignment pins. CD382 4. Remove the cam chain tensioner pivot cap screw and washer. MD1261 3 MD1251 5. Bend the washer tabs and remove the two cap screw securing the sprocket to the camshaft. MD1354A 3. Loosen the cap screw on the end of the cam chain tensioner; then remove the two Allen-head cap screws securing the tensioner assembly and remove the assembly. Account for a gasket. MD1136 MD1245 www.mymowerparts.com MD1137 3-15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. NOTE: Care should be taken not to drop the C-ring down into the crankcase. 9. Remove the four cylinder head cap screws and washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side. MD1131 MD1167 7. Note the timing marks for installing purposes; then drop the sprocket off the camshaft. While holding the chain, slide the sprocket and camshaft out of the cylinder head. Account for an alignment pin. 10. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. MD1163 MD1132 NOTE: Loop the chain over the cylinder and secure it with a wire to keep it from falling into the crankcase. 8. Remove the cam chain tensioner by lifting it from the chain cavity; then remove the two lower nuts securing the cylinder head to the cylinder, one in front and one in rear. AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. 11. Remove the cam chain guide. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. www.mymowerparts.com 3-16 MC1192 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston. 14. Using an awl, remove one piston-pin circlip. Take care not to drop it into the crankcase. MD1173 C. Cylinder D. Piston NOTE: Steps 1-11 in the preceding sub-section must precede this procedure. 12. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half. Account for the washers. MD1213 15. Using the Piston Pin Puller (p/n 0644-328), remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side circlip prior to using the puller. MD1226A 13. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. MD1219 NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder (p/n 0444-006). ! CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. MD1214 AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section. www.mymowerparts.com NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation. When replacing with new rings, replace as a complete set only. If the piston rings must be removed, remove them in this sequence. A. Starting with the top ring, slide one end of the ring out of the ring-groove. 3-17 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT To service piston, see Components sub-section. Servicing Top-Side AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. CC942 Left-Side Components 3. Remove the flange nut securing the starter cup to the crankshaft; then remove the starter cup. Account for the O-ring inside the cup. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. CC943 4. Remove the gear shift stopper (located above the hi/low shift shaft). Account for the washer, spring, and stopper. Removing Left-Side Components A. Cover/Stator Assembly 1. Remove the two cap screws securing the starter to the crankcase; then remove the starter. 2. Remove the four cap screws securing the recoil cover to the left-side cover; then remove recoil cover. CC944 NOTE: Remove the two cap screws securing the speed sensor housing; then remove the housing. Account for the gasket. www.mymowerparts.com 3-18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. CF109 5. Remove the cap screws securing the left-side cover to the crankcase (fifteen 6 mm and one 8 mm); then using an appropriate slide hammer and Slide Hammer 6 mm Adapter (p/n 0644-310), remove the left-side cover. KEY A. B. C. D. E. Driven Gear Drive Gears #1 & #2 Idler Gear Shift Fork with Pin Shift Shaft F. G. H. I. Starter Idler Gear #1 Starter Idler Gear #2 Starter Clutch Gear Assembly Rotor/Flywheel CC948B 6. Remove the nut securing the rotor/flywheel (I) to the crankshaft; then install the crankshaft protector. CC945 CC514D 7. Using the Magneto Rotor Remover (p/n 0444-075), remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly (H) w/washer. NOTE: Care must be taken that the remover is threaded all the way onto the rotor/flywheel. CC946 NOTE: Inspect the inside of the left-side cover for any shaft washers and spacers that may have come off with the cover. Make sure they are returned to their respective shafts. Also, make sure the alignment pins are in place. B. Rotor/Flywheel C. Idle Gear Assembly NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. NOTE: For steps 6-14, refer to illustration CC948B. CC949 www.mymowerparts.com 3-19 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the starter idler gears (F & G) from the crankcase; then remove the pin. CC953 CC950 11. Remove drive gear #2 (B). Account for washers on both sides of the gear. CC951 CC954 9. Remove the idler gear (C). Account for a washer and a spacer. 12. Remove the sliding dog from the driveshaft. CC966 CC952 10. Remove the shift fork and pin (D). www.mymowerparts.com 3-20 13. Remove the circlip, washer, and drive gear #1 (B) from the driveshaft; then account for the bushing and the spacer. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC955 CC959 15. Remove the gear shift shaft. Account for two shims. 3 CC956 NOTE: Note the orientation of the oil holes on the driveshaft and bushing for installing purposes. CC960 CD552 CC961 16. Remove the secondary stopper camshaft assembly. Account for the two shims. CC958 14. Remove driven gear (A) from the output shaft. www.mymowerparts.com CC962 3-21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Note the alignment dots on the cam plate and camshaft for installing purposes. Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. CC963 17. Remove the Allen-head cap screws from the neutral switch base; then remove the switch. Account for the two contacts and springs. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components A. Oil Filter 1. Using an adjustable Oil Filter Wrench (p/n 0644-389), remove the oil filter. CC964 CC967 CC965 AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. www.mymowerparts.com 3-22 2. If the engine has not been removed, lay the ATV on its left side; then remove the cap screws securing the right-side cover to the crankcase. Remove the cover. Account for the gasket and for two alignment pins. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC968 CC074D NOTE: When removing the right-side cover, account for the release roller guide that it does not fall and cause damage. 4. Remove the release roller assembly. Account for four springs. 5. Remove the centrifugal clutch-shoe nut (left-hand threads) and washer from the driveshaft; then using a primary clutch shoe remover, remove the clutch shoe. 3 ! CAUTION Care must be taken when removing the nut; it has “left-hand” threads. 6. Remove the primary drive one-way clutch from the centrifugal clutch housing. Note the word OUTSIDE stamped on the clutch for assembly purposes. CC070D B. Primary Clutch Shoe C. Primary Clutch D. Centrifugal Clutch Housing NOTE: Steps 1-2 in the preceding sub-section must precede this procedure. 3. Remove the cap screw securing the clutch release arm and remove the arm; then in a crisscross pattern, remove the four cap screws securing the clutch release roller assembly. NOTE: Scribe a reference mark with a marker on the arm and shaft to aid in installing. CF043 7. Using the Clutch Sleeve Hub Holder (p/n 0444-007) to hold the clutch sleeve hub, remove the nut and washer. CC073D www.mymowerparts.com 3-23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC076D 8. Scribe a line across the primary clutch assembly to aid in installing. CC969 AT THIS POINT To service clutch components, see Servicing Right-Side Components sub-section. E. Gear Shift Cam Plate/Guide F. Oil Pump/Oil Strainer NOTE: Steps 1-9 in the preceding sub-sections must precede this procedure. NOTE: Note that the bushings on the crankshaft are directional and that the oil holes align for installing purposes. CC077D 9. Simultaneously, remove the primary clutch assembly and centrifugal clutch housing from their respective shafts. Account for the shims and washers. 10. Remove the nut and washer securing the oil pump drive gear to the crank balancer shaft; then remove the gear and account for the pin, gear, washer, and nut. NOTE: Note that the raised hub of the gear is directed inward for installing purposes. CC078D CC971 www.mymowerparts.com 3-24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC972 11. Remove the gear shift shaft from the crankcase. CC975 ! CAUTION If servicing of the engine/transmission is due to a lubrication-related problem, replace the oil pump. NOTE: For general servicing, it is advisable to disassemble, clean, and inspect the oil pump. If any wear or damage is suspected, replace the oil pump. 14. Remove the circlip securing the oil pump driven gear; then remove the gear. Account for the pin and the washer. CC973 NOTE: Always use a new circlip when installing the oil pump driven gear. 12. Release the tension from the gear shift cam stopper arm spring. CC976 CC974 13. Remove the cap screw securing the gear shift cam plate and guide to the gear shift cam; then remove the cam plate and guide. Account for the guide and five pins. CC977 15. Remove the three Phillips-head screws securing the oil pump; then remove the oil pump. www.mymowerparts.com 3-25 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame . Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. CC978 16. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the O-ring. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves 1. Remove the five right-side 6 mm cap screws (one from inside the case) securing the crankcase halves; then remove the seven left-side 6 mm cap screws. Note the location of the different-lengthed cap screws and a wiring form. CC091D 17. Remove the two Phillips-head cap screws securing the strainer. CC979 CC163D AT THIS POINT To service center crankcase components only, proceed to Separating Crankcase Halves. CC980 www.mymowerparts.com 3-26 2. Remove the four left-side 8 mm cap screws (two from inside the case) securing the crankcase halves. Note the location of the different-lengthed cap screws. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC984 CC981 3. Remove the four right-side 8 mm cap screws securing the crankcase halves. Disassembling Crankcase Half NOTE: For steps 1-10, refer to illustration CC985B. NOTE: To aid in assembling, it is recommended that the assemblies are kept together and IN ORDER. CC982 4. Using an appropriate crankcase separator and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins, a C-ring, and two washers. NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. KEY A. Crank Balancer Assembly B. Crankshaft C. Balancer Drive Gear with Pin D. Countershaft Assembly E. Shift Shaft with Fork F. G. H. I. J. K. Gear Shift Cam Reverse Shift Cam Shift Shaft with 3 Forks Driveshaft Assembly Output Shaft Assembly Reverse Idle Gear CC985B 1. Remove the output shaft assembly (J). 2. Remove the two shift shafts (E and H). 3. Remove the reverse shift cam (G) and spacer. CC983 4. Disengage four forks from the gear shift cam (F); then remove the reverse shifter fork. www.mymowerparts.com 3-27 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC986 5. Remove the gear shift cam (F). CC166D 9. Remove the driven gear from the crank balancer assembly (A). Account for a key. CC987 6. Remove the three remaining forks noting their positions for assembling purposes. AT THIS POINT To service gear shift forks, see Servicing Center Crankcase Components sub-section. 7. Remove the reverse idle gear (K) w/shaft. Account for the bushing, two washers, and the circlip. 8. Simultaneously, remove the driveshaft assembly (I) and countershaft assembly (D). CD832A NOTE: Note that the shoulder of the gear is directed to the outside for assembling purposes. 10. Remove the crank balancer assembly (A). NOTE: When removing the crank balancer assembly, rotate the crankshaft counterweight away from the crank balancer assembly counterweight. 11. Using an appropriate crankshaft remover, push the crankshaft assembly out of the crankcase. AT THIS POINT To service the driveshaft and/or countershaft, see Servicing Center Crankcase Components sub-section. NOTE: For efficiency, if the driveshaft and/or countershaft are not being serviced, it is preferable to leave them assembled. The technician should use discretion and sound judgment. NOTE: Note the alignment marks on the crank balancer driven gear and balancer drive gear to aid in assembly. www.mymowerparts.com 3-28 CC115D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. ! CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary. If the shaft is removed, the shaft nut must be replaced with a new one and the shaft must be re-shimmed. 12. To remove the output shaft and gear, remove the nut, slide the gear off the shaft (account for a shim or shims), and drive the shaft out with a plastic mallet (account for a shim or shims). Servicing Top-Side Components NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. NOTE: Whenever a valve is out of tolerance, it must be replaced. Cleaning/Inspecting Valve Cover NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. CC482D Table of Contents (Servicing Components) NOTE: Critical engine/transmission specifications are located at the beginning of this section. Servicing Top-Side Components .......................... 3-29 Valve Assembly ................................................. 3-29 Piston Assembly ............................................... 3-32 Cylinder/Cylinder Head Assembly ..................... 3-34 Servicing Left-Side Components ......................... 3-37 Recoil Starter .................................................... 3-37 Measuring Shift Fork (Thickness) ..................... 3-40 Measuring Shift Fork Groove (Width) ............... 3-41 Measuring Shift Fork To Groove (Side Clearance) ............................................... 3-41 Servicing Right-Side Components ....................... 3-41 Primary Clutch Assembly................................... 3-41 Inspecting Oil Pump .......................................... 3-44 Servicing Center Crankcase Components ........... 3-44 Secondary Gears .............................................. 3-44 Crankshaft Assembly ........................................ 3-46 Driveshaft........................................................... 3-47 Countershaft ...................................................... 3-53 2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover. CC130D www.mymowerparts.com 3-29 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. Removing Valves NOTE: Keep all valves and valve components as a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation. CC136D 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer. NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks (p/n 0644-022); then check the valve stem runout using a dial indicator. CC994 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ATV-1082 2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. CC134D 2. Acceptable diameter range (intake valve) must be within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. www.mymowerparts.com 3-30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1004 CC131D 2. Acceptable width range must be within specifications. 3. Push the valve from side to side; then from top to bottom. Measuring Valve Face Radial Runout 4. Maximum “wobble” deflection must not exceed specifications. 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 2. Acceptable inside diameter range must be within specifications. 3. If a valve guide is out of tolerance, it must be replaced. Servicing Valves/Valve Guides/Valve Seats ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator. www.mymowerparts.com If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing. ! CAUTION If any valve is discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind a valve or severe engine damage may occur. Measuring Rocker Arm (Inside Diameter) 1. Using a dial calipers, measure the inside diameter of the rocker arm. 2. Acceptable inside diameter range must be within specifications. Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. 3-31 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Acceptable outside diameter range must be within specifications. Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC994 PISTON ASSEMBLY NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. Cleaning/Inspecting Piston 2. Insert each valve into its original valve location. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head. 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. CC144D NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston. 4. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. ATV-1011A 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters. CC400D www.mymowerparts.com 3-32 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Cleaning/Inspecting Piston Rings 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. ! CAUTION Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston. ATV-1070 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. 3 Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within specifications. ATV-1069 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. CC995 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within specifications, the piston pin must be replaced. CD325 2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. www.mymowerparts.com 3-33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Piston Rings Cleaning/Inspecting Cylinder Head 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. ! CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. ATV-1085B 2. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration). 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. NOTE: The chrome (silver) ring should be installed in the top position. CC996 726-306A ! CAUTION Incorrect installation of the piston rings will result in engine damage. Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. CYLINDER/CYLINDER HEAD ASSEMBLY 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. NOTE: If the cylinder/cylinder head assembly cannot be trued, they must be replaced. 3. Maximum distortion must not exceed specifications. www.mymowerparts.com 3-34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Honing Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications. CC141D Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. 3 CC127D 2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a ball hone. NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder. CC997 Inspecting Cam Chain Guide 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 2. If the chain guide is damaged, it must be replaced. CC998 4. If any measurement exceeds the limit, bore the cylinder and install an oversized piston or replace the cylinder. NOTE: Oversized piston and rings are available in 0.50 mm (0.020 in.) only. www.mymowerparts.com 3-35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. Measuring Camshaft to Cylinder Head Clearance CC127D 1. Remove the adjuster screws and jam nuts. Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced. 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. CC005D 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely. CC283D 2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. Measuring Camshaft Lobe Height NOTE: Do not rotate the camshaft when measuring clearance. 4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. 1. Using a calipers, measure each cam lobe height. MD1261 ATV1013A 2. The lobe heights must not exceed minimum specifications. www.mymowerparts.com 3-36 5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC145D 6. If clearance is excessive, measure the journals of the camshaft. CF060A 2. If damaged, the camshaft must be replaced. Servicing Left-Side Components 3 RECOIL STARTER CC287D NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head. Inspecting Camshaft Spring/Drive Pin KEY 1. Recoil Starter Assy 2. Reel 3. Spiral Spring 4. Ratchet Assy 5. Ratchet 6. Ratchet Guide 7. Nut 8. Rope Assy 9. Cap Screw 10. Starter Cup 11. Nut 0737-034 1. Inspect the spring and drive pin for damage. ! WARNING Always wear safety glasses when servicing the recoil starter. Removing/Disassembling 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the starter. CF061A www.mymowerparts.com 3-37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case; then remove the ratchet guide from the friction plate. CC039D ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. B602D 5. Remove the spring cover, spring, and shaft. 2. Rotate the reel counterclockwise until the notch of the reel is near the rope guide in the case. Guide the rope into the notch and slowly allow the reel to retract until all spiral spring tension is released. B603D 6. Remove the ratchet and account for the pin. B600D ! CAUTION During the disassembly procedure, make sure all spring tension is released before continuing. 3. Remove the nut. B604D 7. Carefully lift the reel free of the case making sure the spiral spring does not accidentally disengage from the case. B601D www.mymowerparts.com 3-38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling/Installing 1. If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a counterclockwise direction until the complete spring is installed. NOTE: The spiral spring must seat evenly in the recoil case. B605D ! WARNING Care must be taken when lifting the reel free of the case. Wear safety glasses to avoid injury. 8. Remove the protective cover from the starter handle and pull the rope out of the handle; then untie the knot in the rope and remove the handle. NOTE: Do not remove the spiral spring unless replacement is necessary. It should be visually inspected in place to save time. If replacement is necessary, follow steps 9-10. 9. Remove the spiral spring from the case by lifting the spring end up and out. Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case. 10. Unwind the rope from the reel and remove the rope. Cleaning and Inspecting 3 B606D 2. Insert the rope through the hole in the reel and tie a knot in the end; then wrap the rope counterclockwise around the reel leaving approximately 50 cm (20 in.) of rope free of the reel. 3. Apply low-temperature grease to the spring and hub. 4. Thread the end of the rope through the guide hole of the case; then thread the rope through the handle and secure it with a double knot. Install the protective cover into the handle. 5. Align the inner hook of the spiral spring with the notch in the reel. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all components. 2. Inspect the springs and ratchet for wear or damage. 3. Inspect the reel and case for cracks or damage. 4. Inspect the shaft for wear, cracks, or damage. 5. Inspect the rope for breaks or fraying. 6. Inspect the spiral spring for cracks, crystallization, or abnormal bends. B605D 6. Install the ratchet onto its pin making sure the end is properly installed on the reel. 7. Inspect the handle for damage, cracks, or deterioration. www.mymowerparts.com 3-39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B604D 7. Install the shaft, spring, and the spring cover. B601D 10. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch of the reel. 11. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract. 12. Pull the rope out two or three times to check for correct tension. NOTE: Increasing the rotations in step 11 will increase spring tension. B603D 13. Place the recoil starter assembly into position on the left-side cover; then tighten the cap screws to specifications. 8. Install the friction plate with the ratchet guide fitting into the ratchet. CC039D B602D 9. While pushing down on the reel, install the nut. Tighten securely. MEASURING SHIFT FORK (Thickness) NOTE: Whenever a shift fork is out of tolerance, replacement is necessary. 1. Using a calipers, in turn measure the thickness of the machined tip of each shift fork. www.mymowerparts.com 3-40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Shift fork to groove side clearance must be within specifications. Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. CC296D 2. Shift fork thickness must be within specifications. MEASURING SHIFT FORK GROOVE (Width) 1. Using a calipers, in turn measure the width of each shift fork groove. PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring/ Assembling) NOTE: Prior to inspecting and measuring components, it is recommended that all components be removed from the primary gear assembly and be cleaned. NOTE: When removing components from the primary gear assembly, account for the bushing that fits into the primary gear. CC288D 2. Shift fork groove width must be within specifications. MEASURING SHIFT FORK TO GROOVE (Side Clearance) CC239D 1. In turn, insert each shift fork into its groove. 2. Using a feeler gauge, measure the clearance between the shift fork and the groove. Inspecting/Measuring Clutch Driven Plate Warpage 1. Inspect each driven plate for warpage and burn marks. 2. In turn place each driven plate on the surface plate; then using a feeler gauge, measure warpage in several locations. www.mymowerparts.com CC292D 3-41 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC245D 3. Maximum driven plate warpage must not exceed specifications. Measuring Clutch Drive Plate (Fiber) Thickness ATV1014 Inspecting Centrifugal Clutch Housing 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 1. Using a calipers, in turn measure the thickness of each drive plate in several locations. 2. If the housing is damaged in any way, the housing must be replaced. Inspecting Primary One-Way Drive 1. Insert the drive into the clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. 3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. Measuring Clutch Spring Length CC243D 2. Drive plate thickness must not exceed minimum specifications. 1. Using a calipers, measure the overall free length of the clutch spring. 3. If the fiber plate tabs are damaged, the plate must be replaced. 4. Inspect the clutch sleeve hub for grooves or notches. If grooves or notches are present, replace the hub. Inspecting Centrifugal Clutch Shoe 1. Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. 2. Inspect the depth of the grooves in the clutch shoes. If any shoe is worn to the bottom of the groove, replace the complete set. ! CAUTION Always replace clutch shoes as a complete set or severe imbalance could occur. www.mymowerparts.com 3-42 CC247D 2. Overall length must not exceed minimum specifications. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Primary Clutch KEY 1. 2. 3. 4. 5. 6. 7. NOTE: When installing the driven plates for ease of installation, make sure they are placed onto the hub with the rounded side of the plates directed down. Pressure Disc Driven Plate Drive Plate Sleeve Hub Primary Gear Assy Washer Washer CF045A 3. Install the pressure plate onto the hub making sure the alignment dots are correctly positioned. 737-731A 1. Place the clutch hub upside down into the primary gear assembly. CF047A CC920 2. Alternately install the drive plates and driven plates onto the hub (starting and ending with a drive plate) making sure the tabs with the notches are all in line with each other. 4. Place the primary gear assembly w/clutch hub assembly in one hand, place the other hand on top of the clutch hub assembly, and flip the assembly over; then lift the primary gear assembly off the clutch hub assembly being careful not to disturb the drive plate notched tab orientation. CC924 CF044A 5. Place the primary gear assembly on a clean, flat surface; then install the primary washer into the assembly. www.mymowerparts.com 3-43 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC239D CC446D 6. Place the clutch hub assembly into the primary gear assembly. Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY GEARS CC926 ! CAUTION The clutch hub and the pressure plate must be seated in the proper position. If any of the incorrect positions are used, the hub and plate will have clearance between them and they will not operate properly. NOTE: The primary clutch assembly is now completely assembled for installation. INSPECTING OIL PUMP NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur. Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft. 1. Inspect the pump for damage. 2. Install the secondary driven output shaft assembly onto the crankcase. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. 3. Mount the indicator tip of the dial indicator on the secondary driven bevel gear. 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary. www.mymowerparts.com 3-44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim. 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Under 0.05 mm (0.002 in.) Shim Correction ATV-0105 Decrease Shim Thickness At 0.05-0.33 mm (0.002-0.013 in.) No Correction Required Over 0.33 mm (0.013 in.) Increase Shim Thickness Checking Tooth Contact NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact. 3 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. 2. Clean the secondary driven bevel gear teeth of old oil and grease residue. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. 4. Install the secondary driven output shaft assembly. 5. Rotate the secondary driven bevel gear several revolutions in both directions. 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations. ATV-0104 Correcting Tooth Contact NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary. If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart. Tooth Contact Contacts at Top Contacts at Root Shim Correction Decrease Shim Thickness Increase Shim Thickness NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted. ! CAUTION ATV-0103 After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures until they are both within tolerance values. www.mymowerparts.com 3-45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. CC289D 3. Acceptable gap range must be within specifications. Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. CC290D 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Acceptable width range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. ATV-1074 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. 3. Zero the indicator and rotate the crankshaft slowly. ! CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications. www.mymowerparts.com 3-46 NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 2-4. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. CD335 ATV-1017 3 2. Acceptable width range must be within specifications. DRIVESHAFT Disassembling CD336 1. In order, remove the reverse dog, circlip, washer, reverse driven gear, and bushing from the driveshaft. CD337 NOTE: The teeth on the bushing must face the 1st driven gear. CD331 2. Remove the 1st driven washer (right side); then remove the 1st driven gear from the driveshaft. CD333 CD339 www.mymowerparts.com 3-47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the 4th driven gear from the driveshaft. Note the four small dogs facing toward the 3rd driven gear for assembling purposes. CD341 3. Remove the 1st driven bushing; then remove the 1st driven washer (left side) from the shoulder of the splined shaft. Remove the 4th driven circlip. CD345 5. Remove the 3rd driven circlip; then remove the 3rd driven lock washer (right side) from the driveshaft. CD342 CD346 CD343 CD348 6. Remove the 3rd driven gear from the driveshaft. CD344 www.mymowerparts.com 3-48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD349 CD354 7. Remove the 3rd driven bushing from the driveshaft. Note the location of the oil feed hole in the bushing and the matching oil supply hole in the driveshaft for assembling purposes. 10. Remove the 5th driven gear from the driveshaft. 3 CC210D 11. In order, remove the 2nd driven circlip, washer, gear, and bushing from the driveshaft. CD351 8. Remove the 3rd driven lock washer (left side) from the driveshaft. Note the tabs facing toward the 5th driven gear for assembling purposes. CD356 CD352 9. Remove the next 3rd driven lock washer (left side) by rotating it out of the groove. Note the groove closest to the 5th driven gear for assembling purposes. CD357 www.mymowerparts.com 3-49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. In order, install the 2nd driven bushing, gear, washer, and circlip onto the driveshaft. CD358 CD359 CD359 AT THIS POINT To service secondary gears, see Servicing Center Crankcase Components in this sub-section. CD358 Assembling CD357 KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Driveshaft 1st Driven Gear 2nd Driven Gear 3rd Driven Gear 3rd Driven Bushing 4th Driven Gear 5th Driven Gear Reverse Driven Gear Reverse Dog Reverse Driven Bushing 3rd Driven Lock Washer Right 3rd Driven Lock Washer Left 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 3rd Driven Lock Washer Left Driveshaft Bearing 1st Driven Bushing 2nd Driven Bushing 2nd Driven Circlip 3rd Driven Circlip 4th Driven Circlip Reverse Driven Washer 1st Driven Washer - Left 1st Driven Washer - Right 2nd Driven Washer Reverse Driven Circlip 737-733A www.mymowerparts.com 3-50 CD356 2. Install the 5th driven gear onto the driveshaft. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD355 3. Install the 3rd driven lock washer (left side). Lock it into the groove closest to the 5th driven gear (as noted in disassembling) by rotating it when it is in the groove. CD351 ! CAUTION It is very important to assure the oil feed hole in the bushing and oil supply hole in the driveshaft align. If not aligned, engine damage will result. 6. In order, install the 3rd driven gear, lock washer (right side), and circlip onto the driveshaft. CD354 4. Install the next 3rd driven lock washer (left side) onto the driveshaft making sure the tabs are facing toward the 5th driven gear. Make sure the tabs intertwine with the first 3rd driven lock washer. CD349 CD348 CD352 5. Install the 3rd driven bushing onto the driveshaft making sure the oil feed hole in the bushing aligns with the appropriate oil supply hole in the driveshaft (as noted in disassembling). www.mymowerparts.com 3-51 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD346 CD343 7. Install the 4th driven gear onto the driveshaft making sure the four small dogs are facing toward the 3rd driven gear as noted in disassembling; then secure with the circlip. CD342A CD345 CD341 9. Install the 1st driven washer (right side) on the shaft making sure it lines up with the groove in the shaft; then turn the washer locking it on the shaft. CD344 8. Install the 1st driven washer (left side) onto the shoulder of the splined shaft; then install the 1st driven bushing and gear. CD340 www.mymowerparts.com 3-52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Slide the reverse driven bushing onto the shaft making sure the oil port in the bushing aligns with the oil port on the shaft. CD334 CD337 ! CAUTION Failure to align the oil ports will result in serious engine damage. 3 11. In order, install the reverse driven gear, washer, circlip, and reverse dog onto the driveshaft. CD331 NOTE: The driveshaft is now completely assembled for installation. COUNTERSHAFT Disassembling 1. Remove the 2nd drive gear from the countershaft. CD336 CD395 CD335 2. Remove the 5th drive gear from the countershaft. www.mymowerparts.com 3-53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD396 CD405 3. Remove the 5th drive washer and 5th drive circlip from the countershaft. 6. Remove the other 4th drive washer from the countershaft. CD397 CD408 Assembling CD400 4. Remove the 3rd drive gear from the countershaft. 5. Remove the 4th drive circlip securing the 4th drive gear on the countershaft; then remove the first 4th drive washer and 4th drive gear. Account for the bushing. KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Countershaft 2nd Drive Gear 3rd Drive Gear 4th Drive Gear 5th Drive Gear 5th Drive Washer 5th Drive Washer Shaft Bearing 4th Drive Bushing 4th Drive Circlip 5th Drive Circlip 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Shaft Bearing Plug 4th Drive Washer 4th Drive Washer Reverse Idle Shaft Reverse Idle Gear Reverse Idle Bushing Reverse Idle Washer Reverse Idle Circlip Retainer Screw 737-733B 1. Install the 4th drive washer onto the countershaft. www.mymowerparts.com 3-54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD408 CD401 2. Install the 4th drive gear making sure the bushing is in position; then install the other 4th drive washer onto the countershaft. Secure with the circlip. 3 CD400 4. Install the 5th drive washer and 5th drive gear onto the countershaft. CD405 CD397 CD406 3. Install the 3rd drive gear; then install the 5th drive circlip onto the countershaft. CD396 5. Install the 2nd drive gear onto the countershaft. www.mymowerparts.com 3-55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD395 NOTE: The countershaft is now completely assembled for installation. MD1024 3. With the key in position, slide the driven gear onto the crank balancer making sure the timing marks are aligned. Assembling Crankcase Half NOTE: For ease of assembly, install components on the left-side crankcase half. NOTE: If the output shaft and gear were removed, make sure that the proper shim is installed. 1. To install the output shaft and gear, place the shaft into position with proper shims, slide the gear onto the shaft, and secure with a new nut tightened to specifications. CD832A 2. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. Install the crank balancer. CC167D MD1334 NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool. CC166D www.mymowerparts.com 3-56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Place the bearing C-ring into position in the crankcase; then install the front shaft and rear shaft assemblies. 7. Place each of the four shift forks into its respective gear or dog as noted during disassembling; then install the gear shift cam. ! CAUTION The bearing pins must be positioned into the crankcase. CD232 3 CD267 5. Simultaneously, install the driveshaft and countershaft assemblies making sure the washer is on the countershaft. CC987 8. Engage the four forks to the gear shift cam; then install the reverse shift cam and spacer. CD232A 6. Install the reverse idle shaft with circlip making sure the oil hole in the shaft is facing downward; then install a washer, bushing, reverse idle gear, and a washer. NOTE: The reverse idle gear is directional. Care must be taken that it is installed correctly. CC986 NOTE: For proper assembling, the cam lock plate must engage the shift cam cutaway. www.mymowerparts.com CC231D 3-57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC988 9. Install the two gear shift fork shafts; then verify that the two crankcase half alignment pins are in place. NOTE: Prior to joining crankcase halves, turn the shift cam to ensure all gears shift properly. CC982 4. From the left side, install the three case half 8 mm cap screws (two inside the case); then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. Joining Crankcase Halves 1. Verify that the shim washer is on the idler shaft; then apply Three Bond Sealant to the mating surfaces. Place the right-side half onto the left-side half. CC981 5. From the left side, install the seven case half 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 6. From the right side, install the five case half 6 mm cap screws (one inside the case); then tighten only until snug. CC102D 2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 3. From the right side, install the four case half 8 mm cap screws; then tighten only until snug. 7. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws (from steps 3-4) until the halves are correctly joined; then tighten to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 8. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws (from steps 5-6) to specifications. www.mymowerparts.com 3-58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. ! CAUTION 3. Place the oil pump into position in the crankcase and secure with the three Phillips-head screws coated with blue Loctite #243. Tighten to specifications. After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to In- stalling Top-Side Components. Installing Right-Side Components A. Oil Strainer/Oil Pump B. Gear Shift Shaft CC978 1. Place the oil strainer with a new O-ring into position beneath the crankcase and tighten securely with the Phillips-head cap screws. 4. Place the washer and pin into position on the oil pump shaft, install the oil pump driven gear, and secure with the circlip. NOTE: Always use a new circlip when installing the driven gear. CC163D 2. Place the strainer cap into position on the strainer making sure the O-ring is properly installed and secure with the cap screws; then install and tighten the oil drain plug to specifications. CC976 5. Place the gear shift cam plate and guide onto the gear shift cam making sure the alignment pin was installed. Secure assembly with the cap screw coated with blue Loctite #243. Tighten securely. CC091D CC975 www.mymowerparts.com 6. Attach the spring to the gear shift cam stopper arm. 3-59 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC974 7. Install the gear shift shaft. CD447 9. Place the chain into the crankcase; then secure it from the top side with a wire for ease of installing. CC973 C. Primary Driven Gear D. Primary Clutch E. Centrifugal Clutch Shoe CC079D 10. Install the primary driven washers and shims onto the driveshaft and crankshaft. NOTE: Steps 1-7 in the preceding sub-section must precede this procedure. 8. Install the spacer, pin, and oil pump drive gear onto the crank balancer shaft making sure the shoulder of the drive gear is facing inward toward the crankcase; then secure with the washer and nut (threads coated with red Loctite #271) tightened to specifications. ! CAUTION The clutch sleeve hub and the clutch pressure plate must be seated in the proper position. If any of the incorrect positions are used, the hub and plate will have clearance between them and they will not operate properly. 11. Simultaneously, place the primary clutch assembly and the centrifugal clutch housing on their respective shafts making sure the sleeve is properly positioned in the primary assembly. MD1017 CC078D www.mymowerparts.com 3-60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: After placing the primary clutch assembly onto the shaft, pull out on the pressure plate tower to ensure the pressure plate has engaged the clutch hub properly and make sure the plates (drive and driven) are brought together tightly prior to tightening the nut securing the clutch assembly. 12. Using a clutch sleeve hub holder, install the nut and washer. Tighten to specifications. NOTE: The washer is directional. Care must be taken to install it correctly. CD440 15. Install the release roller assembly making sure the four springs are in position; then using a crisscross pattern, tighten the four cap screws securely. NOTE: Tighten the four roller assembly cap screws in a crisscross pattern making sure there is no clearance between the clutch plates when secured. CD448 13. Place the primary drive one-way clutch into the centrifugal clutch housing noting the word OUTSIDE for proper placement. CC074D 16. Install the clutch release arm and release roller guide making sure the release roller and guide are aligned. CF043 14. Install the centrifugal clutch shoe and washer; then secure with the centrifugal clutch-shoe nut (left-hand threads). Tighten to specifications; then using a center punch, stake the nut. CD166A 17. Secure the clutch release arm with the cap screw coated with blue Loctite #243. Tighten securely. www.mymowerparts.com 3-61 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 20. Using the oil filter wrench, install a new oil filter. CC073D F. Oil Filter CC967 NOTE: Steps 1-17 of the preceding sub-sections must precede this procedure. NOTE: Lubricate all internal components with 5W-30 oil prior to installing the right-side cover. Installing Left-Side Components NOTE: Care should be taken that the alignment pins are installed in the right-side cover. A. Idle Gear Assembly B. Magneto Rotor 1. Place the starter into position on the crankcase and secure with the cap screws. Note the position of the wiring form. CC989 18. Place the gasket and right-side cover into position making sure the release roller guide remains correctly positioned; then install the fifteen cap screws. CC065D 2. Place the neutral switch base assembly into position making sure the two neutral contacts and springs are inside the case and properly positioned. Secure with Allen-head screws. CD441 19. Tighten the cap screws in a crisscross pattern to specifications. www.mymowerparts.com 3-62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC964 3. Install the secondary stopper camshaft w/one inner shim and one outer shim. CC960 5. Install the driven gear onto the output shaft. 3 CC959 CC962 NOTE: Care must be taken that the alignment dots on the camshaft plate and the camshaft are properly aligned. 6. Place the bushing and washer onto the driveshaft making sure the oil hole of the bushing aligns with the oil hole of the driveshaft. CD552 CC963 4. Install the gear shift shaft w/one inner washer and one outer washer. 7. In turn on the driveshaft, install drive gear #1 and a washer; then secure with the circlip. www.mymowerparts.com 3-63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Install the drive idler gear with one spacer and one washer. CC955 8. Place the select sliding dog gear onto the driveshaft; then place a washer, drive gear #2, and another washer onto the driveshaft. CC952 11. Install starter idler gear #2 and shaft with the chamfered side directed toward the crankcase. CC966 CD140 12. Install the starter clutch gear assembly onto the crankshaft. Place the key into its notch. Place the magneto rotor into position on the crankshaft; then install the magneto rotor nut on the crankshaft and tighten until the rotor is properly seated. Tighten to specifications. CC954 9. Place the gear shift fork into the sliding dog; then install the gear shift fork shaft. CC991 www.mymowerparts.com 3-64 CC953 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC990 13. Install the two alignment pins into the left crankcase half. NOTE: Make sure that three washers and two alignment pins are in place. CC945 16. Place the gear shift stopper w/spring and washer into position above the hi/low shift shaft making sure the spring and stopper are correctly positioned. Tighten to specifications. 3 CC993 CC948A C. Cover D. Speedometer Drive E. Hi/Low Shifter Assembly F. Recoil Starter NOTE: Steps 1-13 in the preceding sub-section must precede this procedure. 17. Place the speed sensor into position and secure with the two cap screws. Tighten securely. ! CAUTION Make sure the speedometer gear and output shaft gear match up during assembly. 14. Place the gasket and left-side cover into position on the crankcase. NOTE: It may be necessary to push or pull the splined Hi/Low range shift shaft to establish cover/crankcase mating. 15. Install the fifteen 6 mm cap screws and one 8 mm cap screw to secure the left-side cover. Only finger-tighten at this time. CF109 18. Place the starter cup into position on the crankshaft making sure a new, lubricated O-ring is inside the cup. Tighten the flange nut to specifications. www.mymowerparts.com 3-65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Top-Side Components A. Piston B. Cylinder CC943 19. In a crisscross pattern, tighten the cap screws (from step 15) to specifications. KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. Cylinder Stud Bolt Stud Bolt Bolt Bolt Bolt Nut Cylinder Gasket Pin 0737-039 NOTE: If the piston rings were removed, install them in this sequence. CD429 20. Place the recoil starter assembly into position on the left-side cover; then tighten four cap screws to specifications. A. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. CD431 ATV-1085B B. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration). NOTE: The chrome (silver) ring should be installed in the top position. www.mymowerparts.com 3-66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase. ! CAUTION ATV-1024 The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. ! CAUTION Incorrect installation of the piston rings will result in engine damage. 1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip is directed upwards or downwards. 3 NOTE: The piston should be installed so the arrow points toward the exhaust. MD1345 4. Loosely install the two nuts with washers which secure the right-side of the cylinder to the right-side crankcase half. NOTE: The two cylinder-to-crankcase nuts will be tightened in step 9. MD1213 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. CF162A MD1344 www.mymowerparts.com 3-67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder Head D. Valve Cover 6. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity. ! CAUTION Keep tension on the cam chain to avoid damaging the crankcase boss. KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cylinder Head Assy Valve Guide Ring Pin Cap Screw Cylinder Head Gasket Pin Gasket Nut Cap Screw Cap Screw Washer Cap Screw 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Cap Screw Plug Gasket Spark Plug Inspection Cap O-Ring Cap Screw Plug O-Ring Insulator Screw Intake Manifold MD1347 0737-038 NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the chain guide into the cylinder. ! CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. MD1349 www.mymowerparts.com 3-68 MD1163 7. Install the four cylinder head cap screws with washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side. Tighten only until snug. MD1270 8. Install the two lower nuts securing the cylinder head to the cylinder, one in front and one in rear. Tighten only until snug. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1192 732-307B 9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to specifications; then tighten the nuts (from step 8) to specifications. Tighten the cylinder-to-crankcase nuts (from step 4) to specifications. 14. Place the C-ring into position in its groove in the cylinder head. 10. With the timing inspection plug removed and the chain held tight, rotate the crankshaft until the piston is at top-dead-center. 3 11. Install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer. MD1131 NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. CD383 12. With the alignment pin installed in the camshaft and the cam lobes directed down (toward the piston), place the camshaft in position and verify that the timing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface. NOTE: When the camshaft assembly is seated, make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket. 13. Loosely place the cam sprocket (with the recessed side facing the camshaft lobes) onto the camshaft and place it into position with the cam chain over the sprocket. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft is necessary for alignment, do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position. 15. When the camshaft assembly is seated, ensure the following. A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. ! CAUTION www.mymowerparts.com If any of the above factors are not as stated, go back to step 10 and carefully proceed. 3-69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole. MD1137 ATV-1027 18. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271). Tighten to specifications; then bend the tab to secure the cap screw. CF030B ! CAUTION Care must be taken that the tab washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. 17. Apply red Loctite #271 to the first cap screw securing the sprocket and tab washer to the camshaft; then install the cap screw. Tighten cap screw only until snug. MD1137 19. Rotate the crankshaft until the first cap screw securing the sprocket to the camshaft (from step 17) can be addressed; then install the cap screw. Tighten to specifications; then bend the tab to secure the cap screw. 20. Install the cylinder head plug in the cylinder head with the open end facing the cylinder head. 21. Remove the cap screw from the end of the chain tensioner; then account for the plunger, spring, and O-ring. CC404D MD1248 www.mymowerparts.com 3-70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 22. Depress the spring-loaded lock and push the plunger into the tensioner. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 27. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. MD1146 23. Place the chain tensioner adjuster assembly and gasket into position on the cylinder making sure the ratchet side is facing toward the top of the cylinder and secure with the two Allen-head screws. CC999 28. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 27) to specifications. 29. Adjust valve/tappet clearance using the following procedure. NOTE: Use Valve Clearance 0444-078) for this procedure. Adjuster (p/n A. Turn the engine over until the piston reaches top dead center on the compression stroke. MD1254 24. Install the cap screw and spring into the end of the chain tensioner. Tighten securely. B. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. MD1245 25. Loosen the adjuster screw jam nuts; then loosen the adjuster screws on the rocker arms in the valve cover. 26. Apply a thin coat of Three Bond Sealant to the mating surface of the valve cover. Place the valve cover into position making sure the two alignment pins are properly positioned. www.mymowerparts.com CD001 C. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. D. Align the valve adjuster handle with one of the marks on the valve adjuster dial. 3-71 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 E. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until specified valve/tappet clearance is attained. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark. F. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. 30. Place the two tappet covers into position; then install and tighten the cap screws securely. CD818 3. Raise the rear of the engine and place a block under it; then install the propeller shaft and output flange into the rear drive coupler. MD1264 31. If removed, install the spark plug and tighten to specifications. Installing Engine/Transmission CD821 4. Remove the block from beneath the engine; then align the rear drive flanges and secure with four cap screws. Tighten to specifications. NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame; then move it rearward as far as possible. 2. Raise the rear of the engine enough to engage the front driveshaft into the splines of the front drive output yoke; then slide the engine forward as far as possible. CD824 5. Install the lower rear engine mounting through-bolt, spacer, and washer; then install the lower front engine mounting through-bolt, spacer, and washer. Secure with the flange nuts. Tighten to specifications. www.mymowerparts.com 3-72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD809 CC939 6. Connect the crankcase breather vent hose and secure with the clamp. 3 CC938 9. Connect the positive cable to the starter motor and install the protective boot. CC122D 7. Connect the oil cooler hoses to the engine and secure with the clamps. AR604D CC937 10. Connect the battery ground (negative) cable to the crankcase cover. 8. Connect the following electrical components: two wire leads for the oil temperature and oil pressure sensors, indicator lights, CDI, and voltage regulator. www.mymowerparts.com AR600D 3-73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the coil and connect the two wires; then install the high tension lead on the spark plug. 12. Install the carburetor assembly and secure the intake manifold and air inlet boot. CC934 17. Install the air filter housing; then connect the crankcase breather and the inlet air duct. Secure with the clamps. CC120D 13. Route the two vent hoses through the slots in the frame. 14. Connect the speed sensor lead to the wiring harness. CD785 CF172A 15. Place the reverse/high/low shift linkage w/bushing and washer onto the engine shift shaft and secure with the E-clip. CD787 18. Install the exhaust pipe and secure with two cap screws; then install the muffler onto the frame brackets and secure with exhaust springs. CC935 16. Place the gear shift lever into position on the shaft on the engine; then secure with the pinch screw and lock nut. www.mymowerparts.com 3-74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 20. Install the front and rear fender panels and the front and rear racks (see Section 8). 21. Install the storage compartment and steering post access panel; then secure with reinstallable rivets. 22. Install the battery in the tray, install the vent hose. Connect the positive battery cable; then connect the negative cable. Install the battery cover/tool tray. 23. Install the seat. CF137 24. Pour the correct amount of recommended oil into the engine/transmission filler hole; install the filler plug. 3 CF138 19. Connect the gas hose to the fuel pump; then connect the vacuum hose. Secure with hose clamps. ATV-0075 ! CAUTION If the engine had a major overhaul or if any major part was replaced, proper engine break-in procedures must be followed (see Section 1). If the proper engine break-in procedures are not followed, severe engine damage may result. CD766A www.mymowerparts.com 3-75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (400 - Automatic Transmission) 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery vent hose; then remove the battery. ! CAUTION Removing Engine/Transmission ........................... 3-76 Top-Side Components........................................... 3-79 Removing Top-Side Components ......................... 3-79 Left-Side Components .......................................... 3-83 Removing Left-Side Components ......................... 3-83 Right-Side Components ........................................ 3-85 Removing Right-Side Components....................... 3-86 Center Crankcase Components............................ 3-90 Separating Crankcase Halves............................... 3-90 Disassembling Crankcase Half ............................. 3-91 Servicing Components.......................................... 3-93 Assembling Crankcase Half ................................ 3-112 Joining Crankcase Halves................................... 3-115 Installing Right-Side Components....................... 3-116 Installing Left-Side Components ......................... 3-119 Installing Top-Side Components ......................... 3-121 Installing Engine/Transmission ........................... 3-126 Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 3. Remove the front and rear racks (see Section 8). 4. Remove the storage compartment and the steering post access panel (see Section 8). 5. Drain the oil from beneath the engine/transmission. Removing Engine/ Transmission 733-441A Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT 6. Remove the front and rear fender panels (see Section 8). 7. Disconnect the fuel hose (1), carburetor vent hose (2), and the fuel pump vacuum hose (3) from the carburetor. If the technician's objective is to service/replace left-side cover oil seals (3), front output joint oil seal (1), rear output joint oil seal (1), and/or the oil strainer (from beneath the engine/ transmission), the engine/transmission does not have to be removed from the frame. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 1. Remove the seat; then remove the battery cover/tool tray. CF178A 8. Disconnect the crankcase vent hose from the air cleaner housing. Remove the clamp securing the air intake hose to the carburetor; then remove the air cleaner housing. NOTE: The air cleaner intake duct must be removed prior to removing the air cleaner housing. www.mymowerparts.com 3-76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF181 AF962 9. Remove the clamps securing the cooling ducts to the V-belt housing. 14. Remove the cap screws securing the two oil fittings to the crankcase; then route the hoses away from the engine. Account for two O-rings. 10. Remove the cooling ducts from the V-belt cover. 3 CF174 CD793 11. Remove the cap screws securing the left-side foot peg to the footrest. NOTE: There will be a substantial amount of oil draining from the oil hoses when removing. Place a drain pan beneath the hoses prior to removing the cap screws. 15. Remove the two cap screws securing the exhaust pipe to the engine; then remove the exhaust springs from the muffler at the juncture in front of the muffler. CD781 12. Loosen the clamp securing the carburetor to the intake; then route the carburetor assembly up and away from the engine. 13. Remove the E-clip securing the shift rod to the engine shift arm; then allow the shift rod to hang by the pivot axle bolt. CF138 16. Remove the four cap screws securing the rear output shaft to the transmission; then push the shaft to the rear as far as possible. www.mymowerparts.com 3-77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 21. Remove the spark plug wire from the spark plug. 22. Remove the shift indicator connector from the main wiring harness. 23. Remove the cap screw securing the engine ground wire to the engine. 24. Remove the two engine mounting through-bolts. Account for a spacer on the lower front bolt. CD085 NOTE: It is advisable to lock the brake when loosening the cap screws securing the rear driveshaft. 17. Remove the positive cable from the starter motor and route it out of the way. 18. Disconnect the speed sensor lead from the wiring harness. CF193 CF172A 19. Disconnect the stator-to-rectifier/regulator connector. 20. Remove the temperature sensor wires from the engine. CF194 25. Slightly raise the front of the engine to disengage the front driveshaft from the front output yoke. NOTE: There are two temperature sensors. CD096 CC939 www.mymowerparts.com 3-78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 26. Remove the engine from the left side by moving the engine forward while raising the engine in the rear and rotating the engine clockwise. The engine will come out the left side of the frame. Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. MD1264 NOTE: Keep the mounting hardware with the covers for assembly purposes. 2. Remove the 12 valve cover cap screws. Note the rubber washers on the four top-side cap screws; remove the valve cover. Note the orientation of the cylinder head plug and remove it. Note the location of the two alignment pins. NOTE: The engine/transmission does not have to removed from the frame for this procedure. Removing Top-Side Components A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspection plug; then using the recoil starter, rotate the crankshaft to top-dead-center of the compression stroke. MD1261 NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. 1. Remove the cap screws securing the two tappet covers. Remove the two tappet covers. Account for the O-rings. MD1354A 3. Loosen the cap screw on the end of the cam chain tensioner; then remove the two Allen-head screws securing the cam chain tensioner assembly. Remove the tensioner assembly and gasket. www.mymowerparts.com 3-79 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. NOTE: Care should be taken not to drop the C-ring down into the crankcase. MD1245 4. Remove the cam chain tensioner pivot cap screw and washer. MD1131 7. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cylinder head. Account for an alignment pin. NOTE: Loop the chain over the cylinder and secure it with a wire to keep it from falling into the crankcase. MD1251 5. Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft. MD1132 MD1136 MD1137 www.mymowerparts.com 3-80 8. Remove the cam chain tensioner by lifting it from the chain cavity; then remove the two lower nuts securing the cylinder head to the cylinder, one in front and one in rear. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the cam chain guide. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. MD1192 9. Remove the four cylinder head cap screws and washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side. MD1173 C. Cylinder D. Piston NOTE: Steps 1-11 in the preceding sub-section must precede this procedure. 12. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half. Account for the washers. CD211 10. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. MD1226A 13. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. MD1163 AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. www.mymowerparts.com 3-81 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a connecting rod holder. ! CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. MD1214 AT THIS POINT NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation. When replacing with new rings, replace as a complete set only. If the piston rings must be removed, remove them in this sequence. To service cylinder, see Servicing Top-Side Components sub-section. ! CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston. 14. Using an awl, remove one piston-pin circlip. Take care not to drop it into the crankcase. MD1211 A. Starting with the top ring, slide one end of the ring out of the ring-groove. B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. MD1213 15. Using Piston Pin Puller (p/n 0644-328), remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side circlip prior to using the puller. www.mymowerparts.com 3-82 MD1219 AT THIS POINT To service piston, see Components sub-section. Servicing Top-Side AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Left-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT MD1304 To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. 3. Lay the engine/transmission on its right side. Remove the 15 left-side cover-to-crankcase mounting cap screws noting the location of the 8 mm cap screw with the washer near the middle of the left-side cover. Keep the different-lengthed 6 mm cap screws in order for installing purposes. Removing Left-Side Components A. Recoil Starter B. Starter Cup C. Cover/Stator Assembly 1. Remove the four recoil starter cover cap screws. Remove the recoil starter assembly noting the location of the single washer. Note the condition of the recoil cover gasket. Replace if damaged. AT THIS POINT To service the recoil starter, see Servicing Left-Side Components sub-section. MD1186 4. Using Side Case Puller (p/n 0644-262) and the 6 mm adapter, remove the left-side cover w/stator assembly. Note the condition of the gasket. Replace if necessary. Account for the two alignment pins and the position of the shifter bracket for installing purposes. 2. Remove the flange nut securing the starter cup to the crankshaft; then remove the starter cup. Account for the O-ring inside the cup. CC946 MD1303 www.mymowerparts.com 3-83 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Care must be taken that the remover is fully threaded onto the rotor/flywheel or damage may occur. 7. Using Magneto Rotor Remover (p/n 0444-075), break the rotor/flywheel assembly loose from the crankshaft. Remove the remover, the crankshaft protector, the rotor/flywheel, and the starter clutch gear. Account for the key. MD1188 NOTE: Inspect the inside of the left-side cover for any shaft washers that may have come off with the cover. Make sure they are returned to their respective shafts and that the starter idler gear spacer is on the shaft or in the cover. D. Rotor/Flywheel E. Starter Motor NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. MD1368 5. Remove the rotor/flywheel nut. MD1369 MD1194 6. Install the crankshaft protector. MD1370 8. Remove the starter idler gear (No. 1) and starter idler gear (No. 2). MD1365 www.mymowerparts.com 3-84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1078 MD1305 9. Remove the gear shift shaft assembly and washer from the left-side crankcase. Note the positions of the alignment marks and washer for installing purposes; then release the cam stopper spring tension. 14. Remove starter motor by tapping lightly with a mallet. 15. Using an impact screwdriver, remove the three Phillips-head screws holding the crankshaft bearing retainer. Remove the crankshaft bearing retainer. 3 MD1239 10. Remove the shift detent cam. Note position of spacer for installing purposes. MD1122 11. Remove the cam stopper assembly. 12. Remove the spacer from the driveshaft noting the direction of the stepped side for installing purposes. Right-Side Components AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. MD1224 13. Remove two starter motor cap screws. www.mymowerparts.com AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. 3-85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, turn the gas tank valve to the OFF position. Remove the cap screws securing the right-side V-belt cover to the clutch cover. Remove the cover. Note the locations of the long cap screws and the two wire forms. Account for the gasket and for two alignment pins. MD1306 MD1033 3. Remove the movable drive face and spacer. Account for the eight movable drive face rollers and outer drive face cover. MD1035 MD1307 2. Mark the movable drive face and the fixed drive face for installing purposes; then remove the nut holding the movable drive face onto the crankshaft. www.mymowerparts.com 3-86 MD1034 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1036 4. Remove the V-belt. MD1068 7. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. 3 MD1118 5. Remove the fixed drive face. MD1092 8. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of the different-lengthed cap screws for installing purposes. 9. Using a rubber mallet, loosen the clutch cover; then pull it away from the right-side crankcase half. Account for two alignment pins and gasket. MD1094 6. Remove the nut holding the driven pulley assembly; then remove the driven pulley assembly. MD1115 www.mymowerparts.com 3-87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 D. Gear Position Switch E. Centrifugal Clutch Assembly F. Oil Pump Drive Gear G. Oil Pump Driven Gear NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. MD1043 12. Remove the one-way sprag clutch noting the direction of the green dot or the stamp tag OUTSIDE for installing purposes. MD1072 10. Remove the cap screws holding the gear position indicator switch onto the right-side crankcase half. MD1286 13. Remove the left-hand threaded nut holding the centrifugal clutch assembly. ! CAUTION Care must be taken when removing the nut; it has “left-hand” threads. MD1041 11. Remove the gear position indicator switch. Account for two contact pins and two springs. MD1014 MD1040 www.mymowerparts.com 3-88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 17. Remove the snap ring holding the oil pump driven gear. MD1016 14. Remove the cam chain. MD1019 NOTE: Always use a new snap ring when installing the oil pump driven gear. 18. Remove oil pump driven gear. Account for the pin. MD1335 15. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT To service clutch components, see Servicing Right-Side Components sub-section. H. Oil Pump/Oil Strainer MD1018 16. Remove oil pump drive gear. Account for the pin. NOTE: Steps 1-18 in the preceding sub-sections must precede this procedure. 19. Remove three Phillips-head screws holding the oil pump and remove the oil pump. Account for two alignment pins. www.mymowerparts.com MD1017 3-89 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. MD1060 20. Remove the four cap screws securing the oil strainer cover; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. NOTE: Note the directional arrow for installing purposes. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. MD1006 MD1207 AT THIS POINT To service center crankcase components only, proceed to Separating Crankcase Halves. MD1012 2. Using Crankcase Separator/Crankshaft Remover (p/n 0444-009) and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. www.mymowerparts.com 3-90 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Note the location of the bearing alignment pin on the secondary output shaft. 2. Remove the reverse idler gear, spacer, and sleeve. Account for the washers. CC869 NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. MD1325 MD1313 CC870 3. Remove the driveshaft. Disassembling Crankcase Half 1. Remove the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the pinion gear. MD1326 4. Remove the shift fork shaft and the outer shift fork. MD1317 www.mymowerparts.com 3-91 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1327 MD1024 5. Remove snap ring and gear from the output side of the gear cluster. Remove the gear cluster and the inner shift fork together. Account for snap ring, gear, and washer. 9. Using Crankcase Separator/Crankshaft Remover (p/n 0444-009), remove the crankshaft. MD1330 ! CAUTION MD1328 6. Noting the position of the two holes on the end, remove the shift cam assembly. Account for inner and outer washers. Do not remove the remaining output shaft assembly unless absolutely necessary. If the shaft is removed, the shaft nut must be replaced with a new one and the shaft must be re-shimmed. 10. Remove the secondary drive gear/secondary driven gear retaining nut. From inside the crankcase using a rubber mallet, drive out the output shaft assembly. Account for the output shaft, a shim, a washer, and the nut. AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. MD1329 7. Remove the counterbalance gear. Account for the key. 8. Remove the counterbalance shaft. www.mymowerparts.com 3-92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (Servicing Components) NOTE: Critical engine/transmission specifications are located at the beginning of this section. Servicing Top-Side Components .......................... 3-93 Valve Assembly ................................................. 3-93 Piston Assembly ............................................... 3-96 Cylinder/Cylinder Head Assembly ..................... 3-98 Servicing Left-Side Components ....................... 3-101 Recoil Starter .................................................. 3-101 Servicing Right-Side Components ..................... 3-104 Inspecting Centrifugal Clutch Shoe ................ 3-104 Inspecting Centrifugal Clutch Housing ............ 3-104 Inspecting Primary One-Way Drive ................. 3-104 Inspecting Oil Pump ........................................ 3-105 Driven Pulley Assembly ................................... 3-105 Servicing Center Crankcase Components ......... 3-109 Secondary Gears ............................................ 3-109 Crankshaft Assembly ...................................... 3-110 Countershaft ................................................... 3-111 Crank Balancer Driven Gear............................ 3-112 Servicing Top-Side Components 2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover. 3 CC130D ! CAUTION NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. VALVE ASSEMBLY Removing Valves When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. NOTE: Keep all valves and valve components as a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation. NOTE: Whenever a valve is out of tolerance, it must be replaced. Cleaning/Inspecting Valve Cover 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer. NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. www.mymowerparts.com 3-93 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC994 ATV-1082 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. 2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. 2. Acceptable diameter range (intake valve) must be within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width CC134D 1. Using a micrometer, measure the width of the valve face. CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks (p/n 0644-022); then check the valve stem runout using a dial indicator. ATV-1004 2. Acceptable width range must be within specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator. www.mymowerparts.com 3-94 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. If a valve guide is out of tolerance, it must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing. ! CAUTION ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator. If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur. Measuring Rocker Arm (Inside Diameter) 1. Using a dial calipers, measure the inside diameter of the rocker arm. 2. Acceptable inside diameter range must be within specifications. Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. 2. Acceptable outside diameter range must be within specifications. Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC131D 3. Push the valve from side to side; then from top to bottom. 4. Maximum “wobble” deflection must not exceed specifications. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 2. Insert each valve into its original valve location. 2. Acceptable inside diameter range must be within specifications. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head. CC144D www.mymowerparts.com 3-95 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. 4. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. ATV-1011A 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters. CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Cleaning/Inspecting Piston Rings CC994 PISTON ASSEMBLY NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. Cleaning/Inspecting Piston 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. ! CAUTION 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston. 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. Measuring Piston-Ring End Gap (Installed) 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. 1. Place each piston ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must not exceed specifications. www.mymowerparts.com 3-96 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. CC995 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within specifications, the piston pin must be replaced. CC397D 2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. ATV-1070 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. ATV-1085B ATV-1069 2. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston according to the illustration. NOTE: The chrome (silver) ring should be installed in the top position. www.mymowerparts.com 3-97 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 726-306A ! CAUTION Incorrect installation of the piston rings will result in engine damage. CYLINDER/CYLINDER HEAD ASSEMBLY NOTE: If the cylinder/cylinder head assembly cannot be trued, they must be replaced. Cleaning/Inspecting Cylinder Head CC996 Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 3. Maximum distortion must not exceed specifications. ! CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. www.mymowerparts.com 3-98 CC141D Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder. CC997 Inspecting Cam Chain Guide 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 2. If the chain guide is damaged, it must be replaced. Honing Cylinder CC390D 4. If any measurement exceeds the limit, bore the cylinder and install an oversized piston or replace the cylinder. NOTE: Oversized piston and rings are available. The oversized piston and rings are marked for identification. 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications. ATV-1068A Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced. CC127D 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. 2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a ball hone. www.mymowerparts.com 3-99 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC283D CC005D 2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height. 3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely. NOTE: Do not rotate the camshaft when measuring clearance. 4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. ATV1013A 2. The lobe heights must not exceed minimum specifications. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. MD1261 5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance. Measuring Camshaft to Cylinder Head Clearance 1. Remove the adjuster screws and jam nuts. CC145D www.mymowerparts.com 3-100 6. If clearance is excessive, measure the journals of the camshaft. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Left-Side Components RECOIL STARTER CC287D NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head. Inspecting Camshaft Spring/Drive Pin KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Recoil Starter Assy Reel Spiral Spring Ratchet Assy Ratchet Ratchet Guide Nut Rope Assy Cap Screw Starter Cup Nut 1. Inspect the spring and unloader pin for damage. 0737-034 ! WARNING Always wear safety glasses when servicing the recoil starter. Removing/Disassembling 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the starter. CF061A NOTE: With the weight extended, the unloader pin should be flat-side out; with the weight retracted, the unloader pin should be round-side out. CC039D ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. CF060A 2. If damaged, the camshaft must be replaced. 2. Rotate the reel counterclockwise until the notch of the reel is near the rope guide in the case. Guide the rope into the notch and slowly allow the reel to retract until all spiral spring tension is released. www.mymowerparts.com 3-101 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B600D B603D 6. Remove the ratchet and account for the pin. ! CAUTION During the disassembly procedure, make sure all spring tension is released before continuing. 3. Remove the nut. B604D 7. Carefully lift the reel free of the case making sure the spiral spring does not accidentally disengage from the case. B601D 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case; then remove the ratchet guide from the friction plate. B605D ! WARNING B602D 5. Remove the spring cover, spring, and shaft. www.mymowerparts.com 3-102 Care must be taken when lifting the reel free of the case. Wear safety glasses to avoid injury. 8. Remove the protective cover from the starter handle and pull the rope out of the handle; then untie the knot in the rope and remove the handle. NOTE: Do not remove the spiral spring unless replacement is necessary. It should be visually inspected in place to save time. If replacement is necessary, follow steps 9-10. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the spiral spring from the case by lifting the spring end up and out. Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case. 10. Unwind the rope from the reel and remove the rope. Cleaning and Inspecting 3. Apply low-temperature grease to the spring and hub. 4. Thread the end of the rope through the guide hole of the case; then thread the rope through the handle and secure it with a double knot. Install the protective cover into the handle. 5. Align the inner hook of the spiral spring with the notch in the reel. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all components. 2. Inspect the springs and ratchet for wear or damage. 3. Inspect the reel and case for cracks or damage. 3 4. Inspect the shaft for wear, cracks, or damage. 5. Inspect the rope for breaks or fraying. B605D 6. Inspect the spiral spring for cracks, crystallization, or abnormal bends. 6. Install the ratchet onto its pin making sure the end is properly installed on the reel. 7. Inspect the handle for damage, cracks, or deterioration. Assembling/Installing 1. If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a counterclockwise direction until the complete spring is installed. NOTE: The spiral spring must seat evenly in the recoil case. B604D 7. Install the shaft, spring, and the spring cover. B606D 2. Insert the rope through the hole in the reel and tie a knot in the end; then wrap the rope counterclockwise around the reel leaving approximately 50 cm (20 in.) of rope free of the reel. B603D 8. Install the friction plate with the ratchet guide fitting into the ratchet. www.mymowerparts.com 3-103 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. INSPECTING CENTRIFUGAL CLUTCH SHOE B602D 9. While pushing down on the reel, install the nut. Tighten securely. 1. Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. 2. Inspect the depth of the grooves in the clutch shoes. If any shoe is worn to the bottom of the groove, replace the complete set. ! CAUTION Always replace clutch shoes as a complete set or severe imbalance could occur. B601D 10. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch of the reel. 11. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract. 12. Pull the rope out two or three times to check for correct tension. NOTE: Increasing the rotations in step 11 will increase spring tension. 13. Place the recoil starter assembly into position on the left-side cover; then tighten the cap screws to specifications. ATV1014 INSPECTING CENTRIFUGAL CLUTCH HOUSING 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Insert the drive into the clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. 3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. www.mymowerparts.com 3-104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. CD048 3. Install the pilot bushing with the machined end directed down; then fit the bushing into the pulley hub. 3 CC446D DRIVEN PULLEY ASSEMBLY Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Secure Driven Pulley Compressor (p/n 0444-140) in a suitable holding fixture such as a bench vise; then remove the wing nut, holding handle, flat washer, and pilot bushing leaving the large spacer on the compressor tool base. CD067 4. Using a suitable marking pen, make alignment marks on the fixed face spring holder and both pulley faces. CD049 CD047 2. Place the driven pulley assembly onto the compressor tool base engaging the dowel pins into appropriate holes in the fixed face of the assembly. 5. Place the holding handle on the spring holder fitting the two dowel pins into the spring holder face; then install a flat washer and the wing nut. Turn the wing nut down until resistance is felt. NOTE: Do not use the wing nut to compress the spring further. www.mymowerparts.com 3-105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Release the preload slowly; then continue to relax the spring until the wing nut is flush with the end of the threads. 9. Firmly holding the spring and spring holder, remove the wing nut; then remove the spring. CD050 ! WARNING The spring assembly is under pressure. Extreme care must be taken when relaxing the spring. Always wear safety glasses. Use proper tools only. 6. Using a spanner and suitable breaker bar, loosen the notched-ring nut; then spin the nut free of the hub. CD053 10. Using a thin pry-bar or screwdriver, work the movable face sleeve upward and free of the O-rings; then remove the sleeve. CD051 7. Firmly hold the handle and slowly turn the wing nut counterclockwise to relax the spring. NOTE: There will be a tendency for the handle to rotate clockwise approximately ¼ turn as the spring holder clears the flats or hub. This is due to a slight counterclockwise preload on the spring. CD054 11. Remove the three pins and spacers from the cam slots in the movable face; then remove the movable face. CF091 CD052 www.mymowerparts.com 3-106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling 1. Place the fixed face of the driven pulley on the pulley compressor base making sure the dowel pins are engaged in the appropriate holes in the pulley face. NOTE: Make sure the spacer is on the base or damage to the fixed face will occur when the spring is compressed. CD056 Inspecting 1. Inspect the pulley faces for wear, galling, or grooving. 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. 3 CD048 2. Apply multi-purpose grease to the O-rings and grease seals on the movable face; then install on the fixed face making sure the alignment marks are properly aligned. CF092A 3. Inspect two grease seals in the movable face for nicks, cuts, or damage. CD060 3. Install the three pins and spacers into the fixed face hub; then pack the cam slots in the movable face with multi-purpose grease. CF095A 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking. CD061 www.mymowerparts.com 3-107 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the movable face sleeve aligning the hole in the spring seat with the spring anchor hole in the movable face. CD052 CF097 5. Install the spring over the hub and movable face sleeve; then insert the end of the spring through the sleeve and into the spring anchor hole in the movable face. 8. Compress the spring until the spring holder nears the threads on the fixed face hub; then using the handle, wind the spring holder counterclockwise to align the flats of the spring holder and hub. CD052A CF089A 6. Place the spring holder on the spring engaging the spring end with the appropriate anchor hole. 9. Continue compressing the spring while guiding the spring holder onto the hub. When a slight resistance is felt, stop turning the wing nut. 10. Install the nut (threads coated with red Loctite #271); then tighten the nut to specification using the spanner and a torque wrench. CF087A 7. Assemble the notched-ring nut, spring holding handle, one flat washer, and the wing nut in order on the pulley compressor bolt; then thread the wing nut onto the bolt. www.mymowerparts.com 3-108 CD066 11. Remove the wing nut, washer, and holding handle; then remove the driven pulley from the pulley compressor. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY GEARS NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur. Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft. 2. Install the secondary driven output shaft assembly onto the crankcase. 3. Mount the indicator tip of the dial indicator on the secondary driven bevel gear. Backlash Measurement Shim Correction Under 0.05 mm (0.002 in.) Decrease Shim Thickness At 0.05-0.33 mm (0.002-0.013 in.) No Correction Required Over 0.33 mm (0.013 in.) Increase Shim Thickness Checking Tooth Contact NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. 2. Clean the secondary driven bevel gear teeth of old oil and grease residue. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. 4. Install the secondary driven output shaft assembly. 5. Rotate the secondary driven bevel gear several revolutions in both directions. 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations. 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim. ATV-0103 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. ATV-0105 www.mymowerparts.com 3-109 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-0104 Correcting Tooth Contact NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary. If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart. Tooth Contact Shim Correction Contacts at Top Decrease Shim Thickness Contacts at Root Increase Shim Thickness NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted. ! CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures until they are both within tolerance values. CC290D 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. CC289D 3. Acceptable gap range must be within specifications. www.mymowerparts.com 3-110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. 2. Acceptable width range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft. ATV-1017 2. Acceptable width range must be within specifications. COUNTERSHAFT ! CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction. In either case, complete disassembly and assembly will be required. ATV-1074 3. Zero the indicator and rotate the crankshaft slowly. ! CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. Disassembling 1. Remove the reverse driven gear dog; then remove the circlip securing the reverse driven gear. 2. Remove the reverse driven gear and account for the washer, bushing, and bearing. 4. Maximum runout must not exceed specifications. 3. Remove the low driven gear washer; then remove the low driven gear. Account for the bushing and bearing. NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 2-4. 4. Remove the washer; then remove the circlip securing the sliding dog. Remove the sliding dog. Measuring Crankshaft (Web-to-Web) 5. Remove the high driven gear circlip; then remove the high driven gear. Account for the washer, bushing, and bearing. 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. www.mymowerparts.com 3-111 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Disassembling 1. Remove the small and large washers from the balancer shaft. 2. Note the position of the alignment marks for assembling purposes; then remove driven gear #1 with driven gear #2. Account for pins and springs. 3. Remove driven gear #2 from gear #1; then account for a large washer and a key. Inspecting KEY 1. 2. 3. 4. 5. 6. Reverse Driven Gear Dog Reverse Driven Gear Circlip Bearing Countershaft Low Driven Gear 7. 8. 9. 10. 11. 1. Inspect the gear, pins, and keyway for wear. Bushing High Driven Gear Sliding Dog Lock Washer Lock Washer 2. Inspect the springs for damage or fatigue. Assembling 737-053A 1. Place the high driven gear onto the countershaft making sure the bearing, bushing, and washer are properly positioned. Secure with the circlip. 2. Place the sliding dog onto the countershaft; then secure with the circlip. Place the washer next to the circlip. 3. Place the low driven gear onto the countershaft making sure the bearing and bushing are properly positioned; then place the washer onto the shaft. 4. Place the reverse driven gear onto the countershaft making sure the bearing, bushing, and washer are properly positioned; then secure with the circlip. 5. Place the reverse driven gear dog onto the countershaft; then secure with the circlip. NOTE: The countershaft is now completely assembled for installation. CRANK BALANCER DRIVEN GEAR KEY 1. 2. 3. 4. 5. 6. 7. 8. 3. Place the key and the large washer into position on the balancer shaft. 4. Place the driven gear #1 assembly onto the balancer shaft; then place the large and small washers onto the shaft. NOTE: The crank balancer/driven gear assembly is now completely assembled for installation. Assembling Crankcase Half NOTE: For ease of assembly, install components on the right-side crankcase half. 1. Install the output shaft into the crankcase making sure the two gears, shim, washer, and nut are in the correct order. 737-050A 3-112 2. Using a pair of needle-nose pliers, insert each spring part way into the slot; then install a pin and push the spring/pin assembly into the slot. NOTE: If the output shaft was removed, make sure that the proper shim is installed. Balancer Shaft Washer Driven Gear #1 Driven Gear #2 Spring Key Pin Washer www.mymowerparts.com 1. Place driven gear #2 into driven gear #1; then align the alignment marks of driven gear #1 and driven gear #2. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1199 MD1334 NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installer. 4. Rotate the crankshaft so the counterweight is toward the rear of the engine. Install the counterbalance shaft. MD1079 2. Apply red Loctite #271 to the threads of the output shaft. Install and tighten the nut specifications. Using a punch, peen the nut. MD1024 5. Keeping the counterbalance gear timing mark aligned with the one on the crankshaft gear, install the key and the counterbalance gear. MD1333 3. Apply a liberal amount of oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. CC166D 6. Keeping the two holes facing up, install the shift cam and inner and outer washers. www.mymowerparts.com 3-113 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1329 7. Align the inner shift fork with the gear cluster and with the inner washer in place, install the gear cluster and inner shift fork. While holding the gear cluster in place, install the washer, gear, and snap ring. MD1327 9. Install the input driveshaft. MD1326 MD1032 CC870 MD1198 10. Install the washer, spacer, sleeve, reverse idler gear, and washer. 8. Install the outer shift fork and the shift fork shaft. MD1357 www.mymowerparts.com 3-114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the pinion gear. NOTE: Align the bearing alignment pin on the secondary output shaft. MD1008 4. From the left side, install the remaining crankcase cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws. 3 MD1316 Joining Crankcase Halves 1. Verify that the two alignment pins are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces. Place the right-side half onto the left-side half. CC871 5. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws until the halves are correctly joined; then tighten to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 6. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. MD1336 2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 3. From the right side, install the crankcase cap screws noting the location of the different-sized cap screws; then tighten only until snug. AT THIS POINT After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws. www.mymowerparts.com 3-115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Right-Side Components A. Oil Strainer/Oil Pump 1. Place the oil strainer and new O-ring into position beneath the crankcase. Tighten the Phillips-head screws (coated with red Loctite #271) securely. MD1060 4. Place the pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. ! CAUTION The legs of the strainer must be directed out. NOTE: Always use a new snap ring when installing the oil pump driven gear. MD1337 2. Noting the directional arrow from removing, place the strainer cover into position on the crankcase making sure the O-ring is properly installed and secure with the four cap screws; then tighten the oil drain plug to specifications. MD1020 MD1019 MD1208 3. Place two alignment pins and the oil pump into position on the crankcase and secure with the Phillips-head screws coated with blue Loctite #243. Tighten to specifications. www.mymowerparts.com 3-116 5. Install the cam chain. NOTE: Keep tension on the cam chain to avoid damaging the crankcase boss. 6. Place the pin into position, install the oil pump drive gear, and tighten the cap screw (coated with red Loctite #271) securely. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1017 MD1043 10. Install gear position indicator switch making sure the O-ring is well-oiled and properly positioned. Tighten cap screws securely. 3 MD1018 7. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread). Tighten to specifications. NOTE: The flat side of the flange nut should be directed towards the clutch shoe. ! CAUTION Care must be taken when installing the flange nut; it has “left-hand” threads. 8. Install the one-way sprag clutch making sure that the green dot or the stamp tag OUTSIDE is directed away from the crankcase. MD1040 B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face NOTE: Steps 1-10 in the preceding sub-section must precede this procedure. 11. Install two alignment pins and place the clutch cover gasket into position. Install the clutch cover. MD1286 9. Install gear position indicator switch contact pins and springs into the end of the shift shaft. MD1115 12. Tighten the clutch cover cap screws to specifications. www.mymowerparts.com 3-117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1339 MD1117 13. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; then install and tighten securely. 15. Slide the fixed drive face assembly onto the front shaft. 16. Spread the faces of the driven pulley by pushing the inner face toward the engine while turning it counterclockwise; then when the faces are separated, insert a wedge (approximately 3/8 in. thick) between the faces. Release the inner face. MD1342 14. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loctite #271). Tighten to specifications. MD1340 17. Place the V-belt into position on the driven pulley and over the front shaft. MD1341 MD1068 www.mymowerparts.com 3-118 NOTE: The arrows on the V-belt should point forward. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 18. Making sure the eight movable drive face rollers are in position, pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft. Coat the threads of the nut with red Loctite #271 and secure the movable drive face. Tighten the nut to specifications. Installing Left-Side Components A. Starter Idler Gears B. Rotor/Flywheel 1. Place the crankshaft bearing retainer into position. Apply red Loctite #271 to the three Phillips-head screws. Install and tighten the three Phillips-head screws securely. MD1338 3 MD1122 2. Install the starter motor and tighten the two cap screws securely. MD1033 3. Install the driveshaft spacer making sure the stepped side is to the inside. NOTE: At this point, the wedge can be removed from between the driven pulley faces. 19. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. 20. Install two alignment pins and place the V-belt cover gasket into position on the clutch cover. Install the V-belt cover noting the position of the long cap screws and rubber washer and two wire forms. In a crisscross pattern, tighten cap screws to specifications. MD1224 4. Install the shift detent cam making sure the spacer is properly positioned. www.mymowerparts.com MD1306 3-119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cover D. Recoil Starter NOTE: Steps 1-8 in the preceding sub-section must precede this procedure. 9. Install two alignment pins and place the left-side cover gasket into position. Install the left-side cover. Noting the different-lengthed 6 mm cap screws, the position of the shifter bracket, and the location of the long cap screw with the washer, tighten cap screws only until snug. MD1086 5. Install the cam stopper assembly. 6. Install the gear shift shaft assembly and washer making sure to align the alignment marks. MD1186 10. Install the starter cup making sure that the O-ring is in place inside the starter cup. Tighten the nut w/lock washer to specifications. MD1239 7. Install starter idler gear (No. 1) and starter idler gear (No. 2). MD1304 MD1305 8. Place the key into its notch; then slide the rotor/ flywheel (with the ring gear in place) over the crankshaft. Tighten the nut to specifications. MD1303 11. Tighten the cap screws (from step 9) in a crisscross pattern to specifications. www.mymowerparts.com 3-120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Place the gasket, recoil starter assembly, and cover into position on the left-side cover making sure the single washer is properly positioned; then install and tighten the four cap screws to specifications. Installing Top-Side Components A. Piston B. Cylinder MD1343 ! CAUTION NOTE: If the piston rings were removed, install them in this sequence. A. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. Incorrect installation of the piston rings will result in engine damage. 1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip is directed upwards or downwards. NOTE: The piston should be installed so the arrow points towards the exhaust. ATV-1085B MD1213 NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. B. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston according to the illustration. 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. NOTE: The chrome (silver) ring should be installed in the top position. MD1344 www.mymowerparts.com 3-121 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase. ! CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. C. Cylinder Head D. Valve Cover NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. ! CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. MD1349 MD1345 4. Loosely install the two nuts with washers which secure the cylinder to the right-side crankcase half. NOTE: The two cylinder-to-crankcase nuts will be tightened in step 9. 6. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity. ! CAUTION Keep tension on the cam chain to avoid damaging the crankcase boss. MD1226A MD1347 www.mymowerparts.com 3-122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. While holding the cam chain sprocket to the side, install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer. MD1163 7. Install the four cylinder head cap screws with washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side. Tighten only until snug. CD383 12. With the alignment pin installed in the camshaft and the cam lobes directed down (toward the piston), place the camshaft in position and verify that the timing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface. NOTE: When the camshaft assembly is seated, make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket. MD1270 8. Install the two lower nuts securing the cylinder head to the cylinder, one in front and one in rear. 13. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the camshaft lobes) onto the camshaft and place it into position with the cam chain over the sprocket. MD1359 MD1192 9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to specifications. Tighten the two lower cylinder head nuts (from step 8) to specifications and the cylinder-to-crankcase nuts (from step 4) to specifications. 14. Place the C-ring into position in its groove in the cylinder head. 10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at top-dead-center. www.mymowerparts.com 3-123 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1131 NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft is necessary for alignment, do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position. MD1363 ! CAUTION Care must be taken that the tab washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. 17. Apply red Loctite #271 to the first cap screw securing the sprocket and tab washer to the camshaft; then install the cap screw and tab washer. Tighten cap screw only until snug. 15. When the camshaft assembly is seated, ensure the following. A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. CC404D ! CAUTION If any of the above factors are not as stated, go back to step 13 and carefully proceed. 16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole. MD1137 18. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271). Tighten to specifications; then bend the tab to secure the cap screw. www.mymowerparts.com 3-124 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1137 MD1254 19. Rotate the crankshaft until the first cap screw (from step 17) securing the sprocket to the camshaft can be addressed; then tighten to specifications. Bend the tab to secure the cap screw. 24. Install the cap screw and spring into the end of the cam chain tensioner. Tighten securely. 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards. 3 21. Remove the cap screw from the end of the chain tensioner. Account for the plunger, spring, and O-ring. MD1245 25. Loosen the adjuster screw jam nuts; then loosen the adjuster screws on the rocker arms in the valve cover. 26. Apply a thin coat of Three Bond Sealant to the mating surface of the valve cover; then place the valve cover into position. Note that the two alignment pins are properly positioned. MD1248 22. Depress the spring-loaded lock and push the plunger into the tensioner. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 27. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. MD1146 23. Place the cam chain tensioner assembly and gasket into the cylinder making sure the ratchet side is facing toward the top of the cylinder and secure with the two Allen-head screws. MD1261 www.mymowerparts.com 3-125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 28. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 27) to specifications. 29. Adjust valve/tappet clearance using the following procedure. NOTE: Use Valve Clearance 0444-078) for this procedure. Adjuster (p/n A. Turn the engine over until the piston reaches top-dead-center on the compression stroke. B. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. 31. Install the spark plug and tighten to specifications; then install the timing inspection plug. C. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. Installing Engine/Transmission MD1264 NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame; then slide the engine rearward as far as possible. 2. Slightly raise the rear of the engine and engage the front drive coupler into the splines of the front drive output yoke; then slide the engine forward as far as possible. CD001 D. Align the valve adjuster handle with one of the marks on the valve adjuster dial. E. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until specified valve/tappet clearance is attained. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark. F. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. 30. Place the two tappet covers with O-rings into position; then install and tighten the cap screws securely. www.mymowerparts.com 3-126 CD818 3. Raise the rear of the engine and place a block beneath it; then install the propeller shaft and output flange into the rear drive coupler. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC941 CD821 4. Remove the block from beneath the engine; then align the rear drive flanges and secure with four cap screws. Tighten to specifications. 3 CF138A 7. Install the cooling ducts with clamps and tighten the clamps securely. CD824 5. Install two engine mounting through-bolts, two bushings, and two washers; then tighten the through-bolt flange nuts to specifications. CD515 CD809 6. Secure the exhaust pipe to the engine with two cap screws; then install the muffler and the exhaust springs. CD793 www.mymowerparts.com 8. Secure the engine ground wire to the engine with a cap screw. Tighten to specifications. 3-127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD810 CD787 9. Connect the gear position indicator connector (A), stator connector (B), and the CDI connector (C) to the main wiring harness. CD785 CD797A 10. Connect the temperature sensor leads to the main wiring harness. 11. Secure the wires to the frame with nylon ties. 12. Connect the speed sensor lead to the wiring harness. 13. Secure the positive cable to the starter motor. 14. Secure all wiring to the frame and upper engine bracket with cable ties. CD793 17. Secure the shift rod to the engine with a new E-clip. 15. Secure the two oil hoses to the engine. 16. Secure the crankcase vent hose to the air cleaner housing; then secure the inlet boot and carburetor to the air cleaner housing. CD774 18. Install the front and rear body panels; then install the front and rear racks (see Section 8). www.mymowerparts.com 3-128 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 19. Install the left-side foot peg to the footrest. Tighten securely. 21. Place the storage compartment into position; then install the reinstallable rivets. 22. Place the battery into position in the battery compartment; then install the battery cables and vent hose. Secure with the battery cover. ! CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 23. Add proper amounts of engine/transmission oil. CD782 24. Install the seat. 20. Connect the hose to the fuel pump; then connect the vacuum hose and secure with hose clamps. 3 CD766A www.mymowerparts.com 3-129 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents ! CAUTION (500 - Automatic Transmission/ 650 H1) Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. Removing Engine/Transmission ......................... 3-130 Top-Side Components......................................... 3-134 Removing Top-Side Components ....................... 3-134 Left-Side Components ........................................ 3-138 Removing Left-Side Components ....................... 3-138 Right-Side Components ...................................... 3-141 Removing Right-Side Components..................... 3-141 Center Crankcase Components ......................... 3-145 Separating Crankcase Halves............................. 3-145 Disassembling Crankcase Half ........................... 3-145 Servicing Components........................................ 3-147 Assembling Crankcase Half ................................ 3-166 Joining Crankcase Halves................................... 3-168 Installing Right-Side Components....................... 3-169 Installing Left-Side Components ......................... 3-172 Installing Top-Side Components ......................... 3-175 Installing Engine/Transmission............................ 3-181 3. Remove the radiator access cover, steering post cover, and storage compartment cover assembly; then remove the storage compartment box. 4. Remove the reinstallable rivets securing the side panels; then remove the panels. CD683A Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. 5. Remove the instrument pod; then remove the front rack and front body panel (see Section 8). 6. Drain the oil from beneath the engine/transmission; then drain the coolant. AT THIS POINT If the technician's objective is to service/replace left-side cover oil seals (3), front output joint oil seal (1), rear output joint oil seal (1), and/or the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame. Secure the ATV on a support stand to elevate the wheels. 733-441A ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 1. Remove the seat. 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery and the battery vent hose; then remove the battery. CD799A www.mymowerparts.com 3-130 7. Remove the air filter (see Section 2). FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the vacuum hose and the fuel-pumpto-carburetor hose. CD786 CD766A 9. Loosen the clamp securing the air intake duct to the air filter housing. 11. Remove the clamp securing the cooling duct boot to the V-belt housing; then remove the cooling duct boot from the V-belt housing outlet. 3 CD793 CD785 10. Disconnect the crankcase vent hose from the air filter housing. Remove the clamp securing the carburetor intake duct to the air filter housing; then remove the air filter housing. CD515A 12. Remove the left-side foot peg and footwell (see Section 8). CD787 www.mymowerparts.com CD782 3-131 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Secure the carburetor assembly up and away from the engine. 14. Remove the E-clip securing the shift rod to the engine shift arm; then allow the shift rod to swing forward and hang straight down from the shift lever. 18. Remove the cap screws securing the rear driveshaft/output flange to the rear output joint flange. CD805 CD774 15. Remove the springs securing the muffler to the exhaust pipe; then remove the muffler. Account for the two exhaust springs. CF138A 16. Remove the two cap screws securing the exhaust pipe to the cylinder head; then remove the pipe. NOTE: It is advisable to lock the brake when loosening the cap screws securing the rear driveshaft. 19. Remove the positive cable from the starter motor and route it out of the way. CD796 20. Disconnect the speed sensor connector from the sensor housing. CD794 CD803 17. Remove the two coolant hoses from the engine; then route the hoses out of the way. www.mymowerparts.com 3-132 21. On the right-side, disconnect the gear position indicator connector (A), stator connector (B), and the CDI connector (C). FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD797A CD810 22. Disconnect the temperature sensor lead from the wiring harness. 25. Remove the two engine mounting through-bolts. Account for a washer and a spacer on the bolts. 3 CD788 CD809 23. Remove the spark plug wire from the spark plug; then remove the coil from the frame. 26. Raise the rear of the engine enough to allow the rear output flange to clear the output flange joint. Block the engine up in this position. CD814 24. Remove the cap screw securing the engine ground wire to the engine. CD811 27. Remove the first small boot clamp; then remove the output flange and driveshaft from the rear drive coupler. www.mymowerparts.com 3-133 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD812A CD773 Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. CD813 28. Remove the block from under the engine and lower the engine; then remove the boot clamp from the front output drive yoke. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to removed from the frame for this procedure. Removing Top-Side Components CD818 29. Move the engine to the rear enough to allow the front driveshaft to clear the front output yoke; then move the engine forward and to the left. The engine will come out the left side of the frame. A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspection plug; then using the recoil starter, rotate the crankshaft to top-dead-center of the compression stroke. 1. Remove the two tappet covers. www.mymowerparts.com 3-134 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC001D CD211A NOTE: Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated. 3. Loosen the cap screw on the end of the tensioner; then remove the two Allen-head cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket. 2. Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the cylinder head plug. Note the location of two alignment pins. 3 CC009D 4. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. CD205 CD206 NOTE: Care should be taken not to drop the C-ring down into the crankcase. CC012D 5. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft. www.mymowerparts.com 3-135 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC013D CC017D 6. Remove the cap screw securing the chain tensioner (account for a washer); then remove the tensioner. CC018D CC014D 7. While holding the chain, slide the sprocket and camshaft out of the cylinder head. CC016D 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide. CC266D NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. 8. Remove the five nuts securing the cylinder head to the cylinder; then remove the four cylinder head cap screws with copper washers (note location of the different-sized cap screws and nuts). CC020D www.mymowerparts.com 3-136 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC024D 3 CC022D C. Cylinder D. Piston CC025D NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. 10. Loosen the clamp securing the coolant hose to the union; then detach the hose. 11. Remove the two nuts securing the cylinder to the crankcase. CC026D AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section. ! CAUTION CC023D 12. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston. 13. Using an awl, remove one piston-pin circlip. www.mymowerparts.com 3-137 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. Left-Side Components CC032D 14. Using the Piston Pin Puller (p/n 0644-328), remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side circlip prior to using the puller. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Left-Side Components CC033D NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder (p/n 0444-006). ! CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation. When replacing with new rings, replace as a complete set only. If the piston rings must be removed, remove them in this sequence. A. Starting with the top ring, slide one end of the ring out of the ring-groove. B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT To service piston, see Components sub-section. www.mymowerparts.com 3-138 Servicing Top-Side A. Recoil Starter/Outer Magneto Cover B. Water Pump C. Cover D. Rotor/Flywheel NOTE: The 500 and certain 650 H1 models are equipped with a recoil starter. 1. Remove the four cap screws securing the recoil starter/outer magneto cover to the left-side cover; then remove the recoil starter/outer magneto cover. Account for the gasket. AT THIS POINT To service the recoil starter, see Servicing Left-Side Components sub-section. 2. Remove the flange nut securing the starter cup/spacer to the crankshaft; then remove the starter cup/spacer. Account for the O-ring inside the cup. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD925A CD214 3. Using a cold chisel, scribe a mark showing the relative position of the shift arm to the shift arm shaft to aid in installing; then remove the shift arm. 6. Remove the two cap screws securing the water pump to the engine; then remove the water pump. AT THIS POINT To service the water pump, see Section 4. 7. Remove the cap screws securing the left-side cover to the crankcase noting the location of the different-sized cap screws for installing purposes. 8. Using Side Case Puller (p/n 0644-262), remove the side cover. Account for a gasket and two alignment pins. FI085A 4. Remove the two cap screws securing the speed sensor housing; then remove the housing. Account for the gasket and two seal washers. NOTE: Inspect the inside of the left-side cover for any shaft washers that may have come off with the cover. Make sure they are returned to their respective shafts and that the starter idler gear spacer is on the shaft or in the cover. CD920A 5. Loosen the clamps securing the coolant hose to the water pump; then remove the crossover tube from the cylinder head. Account for an O-ring. CF075A 9. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter. NOTE: The puller has left-hand threads. www.mymowerparts.com 10. Using Magneto Rotor Remover Set (p/n 0444-075), remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly and washer. 3-139 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD939A CD140 12. Remove the snap ring securing the water pump drive gear; then remove the gear noting the direction of the sides of the gear for installing purposes. Account for the drive gear alignment pin. CD940A AT THIS POINT To service the magneto assembly, see Section 5. 11. Remove the two starter gears from the crankcase noting the direction of the beveled side of the gears for installing purposes; then remove the two starter gear shafts. CD944 13. Remove the snap ring securing the water pump driven gear; then remove the gear noting the direction of the sides of the gear for installing purposes. Account for the driven gear alignment pin. CD136 CD952A NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. www.mymowerparts.com 3-140 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Remove the shift shaft noting the timing marks for assembling purposes. Account for two washers. Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. FI302 AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components PR430A 15. Remove the gear shift cam plate; then remove the cam stopper and cam stopper spring. Account for two washers. A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. PR434A CD079 2. Remove the nut securing the movable drive face; then remove the face. Account for a spacer. www.mymowerparts.com 3-141 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD963 PR393 7. Remove the cap screws securing the clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Using a rubber mallet, carefully remove the cover. Account for two alignment pins. CD966A 3. Remove the V-belt. 4. Remove the nut securing the fixed driven assembly; then remove the assembly. CD973A ! CAUTION Care must be taken when removing the cover so the cover gasket is not damaged. PR388 5. Remove the fixed drive face. 6. Using an impact driver, remove the cap screws securing the air intake plate; then remove the plate cushion. CD974A NOTE: For steps 8-14, refer to illustration CC829B. NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. www.mymowerparts.com 3-142 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KEY A. Oil Pump Driven Gear B. Oil Pump Drive Gear C. Clutch Shoe Assembly D. One-Way Clutch (Green Dot MUST Show) E. Final Drive Carrier Bearing Housing F. Input Shaft CC829B CF088A 10. Remove the two Allen-head screws securing the shift indicator sensor; then remove the sensor. Account for two neutral contact pins and two springs. 8. Remove the one-way clutch (D) from the clutch housing. Note the location of the green alignment dot (or the word OUTSIDE) for installing purposes. 3 9. Using a hydraulic press, remove the clutch housing assembly from the clutch cover. Account for the left fixed drive spacer and an O-ring inside the fixed drive spacer. CD997 11. Remove the nut (left-hand threads) securing the clutch shoe assembly (C). Account for a washer. CF085 FI279A NOTE: The washer is also directional. The flat side of the washer must face toward the centrifugal clutch assembly when installing. CC596 NOTE: Account for and inspect the clutch housing seal. www.mymowerparts.com 3-143 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Using an impact driver, remove the Allen-head screws securing the final drive carrier bearing housing (E); then remove the housing and account for two alignment pins. FI336A 12. Remove the cap screw securing the oil pump drive gear (B). Account for a cap screw, washer, pin, and spacer. CD999 14. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the direction of the sides of the gear for installing purposes. Account for a pin and a washer. CC606 CD984 CD987 CD895A 15. Using an impact driver, remove the three Phillips-head screws securing the oil pump; then remove the pump. CD993 www.mymowerparts.com 3-144 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD988 CC665 Center Crankcase Components Disassembling Crankcase Half NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For steps 1-7, refer to illustration CC821B. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves 1. Remove the right-side cap screws securing the crankcase halves. Note the location of the different-lengthed cap screws. KEY A. Secondary Driven Shaft Assembly B. Crank Balancer Assembly C. Crankshaft D. Countershaft Assembly E. Driveshaft F. Reverse Idler Gear Assembly G. Gear Shift Shaft H. Shift Shaft with 2 Forks CC821B 2. Remove the left-side cap screws securing the crankcase halves. Note the location of the different-lengthed cap screws. NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 3. Using the Crankcase Separator/Crankshaft Remover (p/n 0444-009) and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. 1. Remove the secondary driven shaft assembly (A) noting the location of the bearing locating pins. Account for the bearing C-ring. NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. www.mymowerparts.com 3-145 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD267 2. Remove the reverse idler gear assembly (F). Account for all washers, shaft, bushing, and the gear. CC674 NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. 6. Using a rubber mallet, tap on the crankcase to remove the driveshaft. CC668 3. Remove the shift shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes. 4. Remove the gear shift shaft (G) noting the location of the two holes on the end of the shaft. Account for two washers. CC675 7. Note the timing marks on the crank balancer assembly (B) gear and crankshaft (C) gear for assembling purposes; then slide the crank balancer gear off the crank balancer. Account for the key in the keyway. PR380A 5. Remove the countershaft assembly (D). Account for a washer on each end of the countershaft. CD826 8. Remove the crank balancer. NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crankshaft. www.mymowerparts.com 3-146 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary. If the shaft is removed, the shaft nut must be replaced with a new one and the shaft must be re-shimmed. CD832B 9. Remove the snap ring securing the water pump driven gear shaft. 13. To remove the assembly, remove the nut securing the secondary drive gear and secondary driven gear; then from the inside of the crankcase using a rubber mallet, remove the output shaft assembly. Account for the output shaft, two gears, a shim, a washer, and the nut. 10. Using a hydraulic press, remove the crankshaft assembly. NOTE: Use a protective end cap to prevent damage to the crankshaft threads. 3 11. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the cap O-ring. CC686 Table of Contents (Servicing Components) NOTE: Critical engine/transmission specifications are located at the beginning of this section. PR407 12. Remove the two cap screws securing the oil strainer; then remove the strainer. Servicing Top-Side Components ........................ 3-148 Valve Assembly ............................................... 3-148 Piston Assembly .............................................. 3-150 Cylinder/Cylinder Head Assembly.................... 3-152 Servicing Left-Side Components ........................ 3-156 Recoil Starter .................................................. 3-156 Servicing Right-Side Components ..................... 3-159 Inspecting Centrifugal Clutch Shoe ................. 3-159 Inspecting Clutch Housing .............................. 3-159 Inspecting Primary One-Way Drive ................. 3-159 Inspecting Oil Pump ........................................ 3-159 Driven Pulley Assembly ................................... 3-159 Servicing Center Crankcase Components ......... 3-163 Secondary Gears ............................................ 3-163 Crankshaft Assembly ...................................... 3-164 Countershaft ................................................... 3-166 PR406 www.mymowerparts.com 3-147 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Servicing Top-Side Components Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. NOTE: Whenever a valve is out of tolerance, it must be replaced. Removing Valves NOTE: Keep all valves and valve components as a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation. 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer. Cleaning/Inspecting Valve Cover NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. 2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained. CC132D 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ! CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover. CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout CC130D www.mymowerparts.com 3-148 1. Support each valve stem end with the V Blocks (p/n 0644-022); then check the valve stem runout using a dial indicator. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1082 2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. 2. Acceptable diameter range (intake valve) must be within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. CC131D 3. Push the valve from side to side; then from top to bottom. ATV-1004 2. Acceptable width range must be within specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator. 4. Maximum “wobble” deflection must not exceed specifications. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 2. Acceptable inside diameter range must be within specifications. 3. If a valve guide is out of tolerance, it must be replaced. www.mymowerparts.com 3-149 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing. ! CAUTION If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur. Measuring Rocker Arm (Inside Diameter) ATV-1011A 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters. 1. Using a dial calipers, measure the inside diameter of the rocker arm. 2. Acceptable inside diameter range must be within specifications. Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. 2. Acceptable outside diameter range must be within specifications. Installing Valves CC132D PISTON ASSEMBLY 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. Cleaning/Inspecting Piston 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. CC144D 2. Insert each valve into its original location. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head. NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. www.mymowerparts.com 3-150 NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston. 4. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. CC280D Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within specifications, the piston pin must be replaced. NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Cleaning/Inspecting Piston Rings 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. ! CAUTION Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston. ATV-1070 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. Measuring Piston-Ring End Gap (Installed) 1. Place each compression ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within specifications. ATV-1069 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. www.mymowerparts.com 3-151 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC127D 726-306A 2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. 3. On the 650 H1, the ring with the orientation mark (MTOP) should be installed in the second (middle) groove and the ring with the orientation mark (M) should be installed in the first (top) groove. Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. ATV-1024A ! CAUTION Incorrect installation of the piston rings will result in engine damage. CYLINDER/CYLINDER HEAD ASSEMBLY ATV-1085B NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. 2. On the 500, install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration). NOTE: The chrome (silver) ring should be installed in the top position. NOTE: If the cylinder/cylinder head assembly cannot be trued, they must be replaced. Cleaning/Inspecting Cylinder Head ! CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. www.mymowerparts.com 3-152 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. 3 CC128D Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. CC129D Inspecting Cam Chain Guide 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 3. Maximum distortion must not exceed specifications. 2. If the chain guide is damaged, it must be replaced. Honing Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications. CC141D Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. www.mymowerparts.com 3-153 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC127D 2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a ball hone. NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder. CC283D 2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height. ATV1013A 2. The lobe heights must not exceed minimum specifications. Inspecting Camshaft Bearing Journal CC390D 4. If any measurement exceeds the limit, replace the cylinder and piston. Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced. 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. www.mymowerparts.com 3-154 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. Measuring Camshaft to Cylinder Head Clearance 1. Remove the adjuster screws and jam nuts. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC005D 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely. NOTE: Do not rotate the camshaft when measuring clearance. CC287D NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head. Inspecting Camshaft Spring/Drive Pin 1. Inspect the spring and drive pin for damage. 4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. CF061A CC003D 5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance. CF060A 2. If damaged, the camshaft must be replaced. CC145D 6. If clearance is excessive, measure the journals of the camshaft. www.mymowerparts.com 3-155 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Left-Side Components RECOIL STARTER KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Recoil Starter Assy Rope Assy Spiral Spring Reel Ratchet Assy Nut Cap Screw Nut Starter Cup O-Ring O-Ring Spacer Oil Seal Bearing B600D ! CAUTION During the disassembly procedure, make sure all spring tension is released before continuing. 3. Remove the nut. 0737-764 Removing/Disassembling 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the starter. B601D 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case; then remove the ratchet guide from the friction plate. CC039D ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. 2. Rotate the reel counterclockwise until the notch of the reel is near the rope guide in the case. Guide the rope into the notch and slowly allow the reel to retract until all spiral spring tension is released. www.mymowerparts.com 3-156 B602D 5. Remove the spring, collar, and friction spring. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the spring from the case by lifting the spring end up and out. Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case. 10. Unwind the rope from the reel and remove the rope. Cleaning and Inspecting B603D 6. Remove the ratchet and account for the pin. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all components. 2. Inspect the springs and ratchet for wear or damage. 3. Inspect the reel and case for cracks or damage. 4. Inspect the shaft for wear, cracks, or damage. 5. Inspect the rope for breaks or fraying. 6. Inspect the spiral spring for cracks, crystallization, or abnormal bends. B604D 7. Carefully lift the reel from the case making sure the spiral spring does not accidentally disengage from the case. 7. Inspect the handle for damage, cracks, or deterioration. Assembling/Installing 1. If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a counterclockwise direction until the complete spring is installed. NOTE: The spiral spring must seat evenly in the recoil case. B605D ! WARNING Care must be taken when lifting the reel free of the case. Wear safety glasses to avoid injury. 8. Remove the protective cover from the starter handle and pull the rope out of the handle; then untie the knot in the rope and remove the handle. NOTE: Do not remove the spiral spring unless replacement is necessary. It should be visually inspected in place to save time. If replacement is necessary, follow steps 9-10. B606D 2. Insert the rope through the hole in the reel and tie a knot in the end; then wrap the rope counterclockwise around the reel leaving approximately 50 cm (20 in.) of rope free of the reel. www.mymowerparts.com 3-157 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Apply low-temperature grease to the spring and hub. 4. Thread the end of the rope through the guide hole of the case; then thread the rope through the handle and secure it with a double knot. Install the protective cover into the handle. 5. Align the inner hook of the spiral spring with the notch in the reel. B602D 9. While pushing down on the reel, install the nut. Tighten securely. B605D 6. Install the ratchet making sure the end is properly installed on the reel. B601D 10. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch of the reel. 11. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract. 12. Pull the rope out two or three times to check for correct tension. B604D 7. Install the friction spring and the spring cover. NOTE: Increasing the rotations in step 11 will increase spring tension. 13. Place the recoil starter assembly into position on the left-side cover; then tighten the cap screws to specifications. B603D 8. Install the friction plate with the ratchet guide fitting into the ratchet. CC039D www.mymowerparts.com 3-158 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING OIL PUMP Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the complete set. CC446D ! CAUTION DRIVEN PULLEY ASSEMBLY Always replace the clutch shoes as a complete set or severe imbalance could occur. Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Secure Driven Pulley Compressor (p/n 0444-121) in a suitable holding fixture such as a bench vise; then remove the wing nut, holding handle, flat washer, and pilot bushing leaving the large spacer on the compressor tool base. ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE CD047 1. Insert the drive into the clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. 2. Place the driven pulley assembly onto the compressor tool base engaging the dowel pins into appropriate holes in the fixed face of the assembly. 3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. www.mymowerparts.com 3-159 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD048 3. Install the pilot bushing with the machined end directed down; then fit the bushing into the pulley hub. CD050 ! WARNING The spring assembly is under pressure. Extreme care must be taken when relaxing the spring. Always wear safety glasses. Use proper tools only. 6. Using a spanner and suitable breaker bar, loosen the notched-ring nut; then spin the nut free of the hub. CD067 4. Using a suitable marking pen, make alignment marks on the fixed face spring holder and both pulley faces. CD051 7. Firmly hold the handle and slowly turn the wing nut counterclockwise to relax the spring. NOTE: There will be a tendency for the handle to rotate clockwise approximately ¼ turn as the spring holder clears the flats or hub. This is due to a slight counterclockwise preload on the spring. CD049 5. Place the holding handle on the spring holder fitting the two dowel pins into the spring holder face; then install a flat washer and the wing nut. Turn the wing nut down until resistance is felt. NOTE: Do not use the wing nut to compress the spring further. CD052 www.mymowerparts.com 3-160 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Release the preload slowly; then continue to relax the spring until the wing nut is flush with the end of the threads. 9. Firmly holding the spring and spring holder, remove the wing nut; then remove the spring. CD056 Inspecting 1. Inspect the pulley faces for wear, galling, or grooving. CD053 10. Using a thin pry-bar or screwdriver, work the movable face sleeve upward and free of the O-rings; then remove the sleeve. 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. CF092A CD054 3. Inspect two grease seals in the movable face for nicks, cuts, or damage. 11. Remove the four pins and spacers from the cam slots in the movable face; then remove the movable face. CF095A 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking. CF091 www.mymowerparts.com Assembling 1. Place the fixed face of the driven pulley on the pulley compressor base making sure the dowel pins are engaged in the appropriate holes in the pulley face. 3-161 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Make sure the spacer is on the base or damage to the fixed face will occur when the spring is compressed. CF097 CD048 2. Apply multi-purpose grease to the O-rings and grease seals on the movable face; then install on the fixed face making sure the alignment marks are properly aligned. 5. Install the spring over the hub and movable face sleeve; then insert the end of the spring through the sleeve and into the spring anchor hole in the movable face. CF089A 6. Place the spring holder on the spring engaging the spring end with the appropriate anchor hole. CD060 3. Install the four pins and spacers into the fixed face hub; then pack the cam slots in the movable face with multi-purpose grease. CF087A CF095A 4. Install the movable face sleeve aligning the hole in the spring seat with the spring anchor hole in the movable face. www.mymowerparts.com 3-162 7. Assemble the notched-ring nut, spring holding handle, one flat washer, and the wing nut in order on the pulley compressor bolt; then thread the wing nut onto the bolt. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY GEARS CD052 8. Compress the spring until the spring holder nears the threads on the fixed face hub; then using the handle, wind the spring holder counterclockwise to align the flats of the spring holder and hub. NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur. Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft. 2. Install the secondary driven output shaft assembly onto the crankcase. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary driven bevel gear. CD052A 9. Continue compressing the spring while guiding the spring holder onto the hub. When a slight resistance is felt, stop turning the wing nut. 10. Install the nut (threads coated with red Loctite #271); then tighten the nut to specification using the spanner and a torque wrench. 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim. 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim. CD066 NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. 11. Remove the wing nut, washer, and holding handle; then remove the driven pulley from the pulley compressor. www.mymowerparts.com 3-163 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Backlash Measurement Shim Correction Under 0.05 mm (0.002 in.) Decrease Shim Thickness At 0.05-0.33 mm (0.002-0.013 in.) No Correction Required Over 0.33 mm (0.013 in.) Increase Shim Thickness Checking Tooth Contact NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. 2. Clean the secondary driven bevel gear teeth of old oil and grease residue. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. 4. Install the secondary driven output shaft assembly. 5. Rotate the secondary driven bevel gear several revolutions in both directions. 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations. ATV-0104 Correcting Tooth Contact NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary. If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart. Tooth Contact Shim Correction Contacts at Top Decrease Shim Thickness Contacts at Root Increase Shim Thickness NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted. ! CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures until they are both within tolerance values. CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) ATV-0103 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. ATV-0105 www.mymowerparts.com 3-164 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Acceptable width range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft. CC290D 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side) 3 ATV-1074 3. Zero the indicator and rotate the crankshaft slowly. ! CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications. 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 2-4. Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. CC289D 3. Acceptable gap range must be within specifications. Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. www.mymowerparts.com ATV-1017 2. Acceptable width range must be within specifications. 3-165 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 COUNTERSHAFT Assembling From the left side: ! CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction. In either case, complete disassembly and assembly will be required. 1. Install the sliding dog (14), driven gear washer (13), and bushing (9). 2. Install bearing (8) and high driven gear (15); then install the left drive gear washer (16). From the right side: 1. Install driven gear washer (13), bushing (9), bearing (8), and low driven gear (12). 2. Install lock washer (11), lock washer (10), washer (6), and bushing (9). 3. Install bearing (8), reverse driven gear (7), washer (6), and the circlip (4). KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Countershaft Drive Gear #2 Reverse Driven Gear Dog Circlip Reverse Driven Gear Spacer Washer Reverse Driven Gear Bearing Bushing Lock Washer Lock Washer 4. Install reverse driven gear spacer (5), circlip (4), reverse driven gear dog (3), and drive gear #2 (2); then install the right drive gear washer (17). 12. 13. 14. 15. 16. 17. Low Driven Gear Driven Gear Washer Sliding Dog High Driven Gear Drive Gear Washer (L) Drive Gear Washer (R) 739-954A NOTE: When installing the countershaft assembly, account for the washer on each end of the shaft. Assembling Crankcase Half Disassembling From the right side: 1. Remove the right drive gear washer (17); then remove drive gear #2 (2). 1. Install the output shaft assembly into the crankcase making sure the two gears, shim, washer, and nut are properly sequenced. 2. Remove the reverse driven gear dog (3); then remove the circlip (4). 3. Remove the reverse driven gear spacer (5); then remove the circlip (4). 4. In order, remove washer (6), reverse driven gear (7), bearing (8), and bushing (9). 5. In order, remove washer (6), lock washer (10, lock washer (11), and low driven gear (12). 6. In order, remove bearing (8), bushing (9), and driven gear washer (13). From the left side: 1. Remove the left drive gear washer (16); then remove the high driven gear (15) and bearing (8). 2. In order, remove bushing (9), driven gear washer (13), and sliding dog (14). www.mymowerparts.com 3-166 CC686 NOTE: The beveled side of the secondary drive gear must face upward. 2. Apply red Loctite #271 to the threads of the output shaft; then secure with the nut. Tighten nut to specifications; then using a punch, peen the nut. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC687 CD832B 3. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. NOTE: It will be necessary to rotate the crank balancer until the counterweight is facing away from the crankshaft; then rotate the crankshaft clockwise into the journal area to allow the crank balancer to be fully seated. 5. Place the key into the crank balancer keyway; then install the crank balancer gear making sure the alignment dots on the crank balancer gear and the crankshaft gear align. CC688 CD826A 6. Install the driveshaft. CC689 NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool. 4. Install the crank balancer. CC675 7. Place a washer on each end of the countershaft assembly; then install the assembly. www.mymowerparts.com 3-167 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the front and rear secondary driven shaft assemblies into the left side of the crankcase making sure the bearing locating pins are facing upward and the bearing C-ring is fully seated in the crankcase. CC674 8. Place a washer on each end of the gear shift shaft; then install the shaft assembly making sure the two holes on the end of the shaft are positioned vertically. 9. Insert the two shift forks into the sliding dogs noting the direction of the tabs from disassembling; then install the shift fork shaft. 12. Place the oil strainer into position; then secure with the two screws. NOTE: Make sure the shift fork tabs face upward and that they are properly seated into the shift cams. 13. Place the oil strainer cap into position making sure the O-ring is in position; then secure the cap with cap screws. Tighten securely. CD268A Joining Crankcase Halves 1. Apply High-Temp Sealant to the left-side mating surface. 2. Lightly oil all bearings and grease all shafts in the right-side crankcase. CC669 10. Install the reverse idler gear assembly noting the positioning of the two washers, gear, bushing, and shaft. 3. Using a propane torch, heat the right-side crankshaft bearing until the oil begins to smoke; then join the two crankcase halves. CC695 CC668 www.mymowerparts.com 3-168 4. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 5. From the right side, install the 8 mm cap screws; then tighten only until snug. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 6. From the left side, install the remaining 8 mm cap screws (two inside the case); then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 7. From the left side, install the case half 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. CD997 8. From the right side, install the 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 3 9. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws (from steps 5-6) until the halves are correctly joined; then tighten to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 10. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws (from steps 7-8) to specifications. CD994 2. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the Allen-head screws securely. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. AT THIS POINT After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components. CD999 Installing Right-Side Components 3. Install the oil pump onto the engine; then tighten the Phillips-head screws securely. 1. Install the shift indicator sending unit making sure the two neutral contact pins and the two springs are properly positioned. Tighten the Allen-head screws securely. www.mymowerparts.com CD988 3-169 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the oil pump drive gear spacer onto the crank balancer shaft. Grease the pin and insert it into the shaft; then install the drive gear making sure the raised side of the gear is facing toward the inside. Secure the gear with the cap screw (threads coated with red Loctite #271) and the washer. Tighten the cap screw to specifications. CD984 NOTE: When installed correctly, the sides of the drive and driven gears will be flush with each other. CD992 6. Install the clutch shoe assembly and secure with the washer (with the flat side facing the assembly as noted in removing) and the nut (threads coated with red Loctite #271). Tighten to specifications. ! CAUTION Care must be taken that the directional washer be installed correctly and note that the nut has left-hand threads. CD991 5. Grease the driven gear pin and insert it into the oil pump shaft; then install the driven gear (noting the direction of the sides of the gear from removing). Secure with a snap ring. FI336A CD985A FI279A 7. Lightly grease the clutch housing seal; then insert the left fixed drive spacer. www.mymowerparts.com 3-170 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Place the clutch cover/clutch housing assembly into position on the crankcase; then secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten to specifications. 12. Place the air intake plate cushion into position; then install the air intake plate. Tighten the cap screws (threads treated with a small amount of red Loctite #271) securely. CF088A 3 CD971 CF086 8. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase. 9. Apply grease to the outer edges of the clutch housing; then from inside the clutch cover, install the clutch housing into the cover using a rubber mallet. 10. Install the one-way clutch onto the clutch shoe assembly. CD970 13. Place the driven pulley assembly into position and secure with the nut. Tighten to specifications. CF084A ! CAUTION When installed correctly, the green alignment dot (or the word OUTSIDE) on the one-way clutch is visible. CC726 14. Slide the fixed drive face onto the shaft. www.mymowerparts.com 3-171 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 15. Spread the faces of the driven pulley by pushing the inner face toward the engine while turning it counterclockwise; then when the faces are separated, insert a wedge (approximately 3/8 in. thick) between the faces. Release the inner face. 19. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to specifications. 16. Place the V-belt into position on the driven pulley and over the front shaft. CD083 PR389 NOTE: The arrows on the V-belt should point forward. Installing Left-Side Components 17. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft. Secure the drive face with a nut (threads coated with red Loctite #271). Tighten the nut to specifications. NOTE: Plug the oil passage in the crankcase housing prior to installing the drive gear/driven gear assembly to prevent loss of an alignment pin. ! CAUTION Make sure the splines extend beyond the drive face or a false torque reading and spline damage may occur. 1. Install the water pump driven gear alignment pin and the driven gear (with the beveled side of the gear facing outward as noted in removing); then secure with the snap ring. CD950A FI428A NOTE: At this point, the wedge can be removed from between the driven pulley faces. 18. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. www.mymowerparts.com 3-172 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD952A CD944 NOTE: The sharp side of the snap ring should be facing outward. NOTE: Once the gears are secured, remove the oil passage plug from the crankcase. 3. Install the two starter gear shafts; then install the two starter gears (with the beveled side of the intermediate gear facing inward as noted in removing). CD949 NOTE: The sharp side of the snap ring should be facing outward. 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing outward as noted in removing); then secure with the snap ring. CD139 CD946A CD145 4. In order on the crankshaft, install a washer, ring gear, key, and the magneto rotor. Secure with the nut (threads coated with red Loctite #271). Tighten to specifications. www.mymowerparts.com 3-173 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the shift cam stopper, spring, and two washers; then coat the threads on the mounting stud with red Loctite #271 and install the nut. Tighten securely. CD948A PR434A 7. Install the shift shaft with two washers making sure to align the timing mark on the shift shaft with the mark on the shift cam plate. CD940B 5. Install the shift cam plate onto the shift cam shaft; then coat the cap screw threads with red Loctite #271 and tighten securely. CD954A CD935A CD927A 8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins. Make sure the outer shift shaft washer is in place. CD934 www.mymowerparts.com 3-174 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Install the crossover tube on the water pump and cylinder head making sure the O-ring is properly positioned. -AGNETO #OVER 'ASKET 3HIFT 3HAFT 7ASHER 15. Install the shift arm on the shift arm shaft making sure the scribed marks (from removing) are aligned. Tighten securely. !LIGNMENT 0IN 16. Place the gasket and recoil starter/outer magneto cover into position on the left-side cover; then tighten four cap screws to specifications. !LIGNMENT 0IN PR431A Installing Top-Side Components 9. Install the magneto cover and secure with the cap screws. Tighten only until snug. 10. Place the starter cup/spacer into position on the crankshaft making sure a new, lubricated O-ring is inside the cup/spacer. Tighten the flange nut to specifications. A. Piston B. Cylinder KEY 1. 2. 3. 4. 5. 6. 7. 8. 3 Cylinder Stud Bolt Nut Cylinder Gasket Pin Water Hose Union Cap Screw O-Ring CD925A 0732-301 11. Tighten the cap screws (from step 9) to specifications. NOTE: If the piston rings were removed, install them in this sequence. 12. Place the speed sensor housing and gasket into position and secure with the two cap screws. Tighten securely. A. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. CD069 13. Place the water pump into position and secure with two cap screws. Tighten securely. www.mymowerparts.com ATV-1085B NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. 3-175 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration). NOTE: On the 500, the chrome (silver) ring should be installed in the top position. On the 650 H1, the ring with the orientation mark (MTOP) should be installed in the second (middle) groove and the ring with the orientation mark (M) should be installed in the first (top) groove. CC032D 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. ATV-1024 CC025D ATV-1024A ! CAUTION Incorrect installation of the piston rings will result in engine damage. 1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip faces upwards. 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase. ! CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. NOTE: The piston should be installed so the arrow points toward the exhaust. www.mymowerparts.com 3-176 CC024D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Loosely install the two nuts which secure the cylinder to the crankcase. ! CAUTION NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10. Care should be taken that the bottom of the chain guide is secured in the crankcase boss. CC023D CC022D 5. Install the coolant hose onto the crankcase union and tighten the clamp. 7. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder. C. Cylinder Head D. Valve Cover CC020D KEY 1. Cylinder Head Assy 2. Valve Guide 3. Pin 4. Cap Screw 5. Cap Screw 6. Cylinder Head Gasket 7. Pin 8. Cap Screw 9. Cap Screw 10. Stud Bolt 11. Stud Bolt 12. Stud Bolt 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Cap Screw Cap Screw Nut Nut Gasket Gasket Spark Plug Inspection Cap O-Ring Cap Screw Stud Bolt Cylinder Head Plug 25. Intake Pipe Assy 26. O-Ring 27. Cap Screw 28. Clamp 29. Temperature Switch Assy 30. Thermostat Cover 31. Thermostat *Frost Plug *Not Illustrated CF057A 0737-755 NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 8. Install the four cylinder head cap screws with copper washers (note the locations of the different-lengthed cap screws). Tighten only until snug. 6. Place the chain guide into the cylinder. www.mymowerparts.com 3-177 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC272D 9. Loosely install the five cylinder head nuts. 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) to 3.8 kg-m (27.5 ft-lb) 500 models, 5.5 kg-m (40 ft-lb) 650 H1; then tighten the 8 mm nut (from step 9) to 2.5 kg-m (18 ft-lb). Using a crisscross pattern, tighten the 6 mm nuts (from step 9) to 1.1 kg-m (8 ft-lb). Tighten the two cylinder-to- crankcase nuts (from step 4) securely. 11. With the timing inspection plug removed and the chain held tight, rotate the crankshaft until the piston is at top-dead-center. CD461 14. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft is necessary for alignment, do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position. 12. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat” the sprocket onto the shaft. CD463 15. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following. 732-307B NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. 13. While holding the cam chain sprocket to the side, install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer. CF013A www.mymowerparts.com 3-178 A. Piston still at top-dead-center. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks parallel to the valve cover mating surface. 18. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) and tighten to specifications. Bend the tab to secure the cap screw. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. ! CAUTION If any of the above factors are not as stated, go back to step 11 and carefully proceed. 16. Place the tab-washer onto the sprocket making sure it covers the pin in the alignment hole. CD465 19. Rotate the crankshaft until the first cap screw (from step 17) can be addressed; then tighten to specifications. Bend the tab to secure the cap screw. ATV1027 ! CAUTION Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. 17. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug. CD466 20. Place the C-ring into position in its groove in the cylinder head. CC012D CD464 21. Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside. www.mymowerparts.com 3-179 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION The open end of the plug must be positioned downward. CD468 24. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until all tension is released; then install the cap screw into the end of the chain tensioner. CD470 22. Remove the cap screw from the end of the chain tensioner; then using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner clockwise until the screw bottoms. CD471 25. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover. CD501 NOTE: The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 24. 23. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two Allen-head cap screws. CC005D 26. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder head and valve cover. www.mymowerparts.com 3-180 CD469 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 E. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until specified valve/tappet clearance is attained. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark. F. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. CC275D 27. Place the valve cover into position. 31. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 28. Install the four top side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. 3 CC001D 32. If removed, install the spark plug. Tighten to specifications. CC003D 29. In a crisscross pattern starting from the center and working outward, tighten the cap screws securely. 30. Adjust valve/tappet clearance using the following procedure. NOTE: Use Valve Clearance 0444-078) for this procedure. Adjuster (p/n A. Turn the engine over until the piston reaches top dead center on the compression stroke. B. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame; then slide the engine rearward as far as possible. 2. Slightly raise the rear of the engine and engage the front drive coupler into the splines of the front drive output yoke; then slide the engine forward as far as possible. C. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. D. Align the valve adjuster handle with one of the marks on the valve adjuster dial. www.mymowerparts.com 3-181 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD818 CD809 3. Raise the rear of the engine and place a block beneath it; then install the propeller shaft and output flange into the rear drive coupler. 6. Secure the exhaust pipe to the engine with two cap screws making sure the mounting brackets engage the frame grommets; then install the muffler and tighten all mounting hardware to specifications. CD821 4. Remove the block from beneath the engine; then align the rear drive flanges and secure with four cap screws. Tighten to specifications. CD803 CF138A 7. Install the cooling ducts with clamps and tighten the clamps securely. CD824 5. Install two engine mounting through-bolts, two bushings, and two washers; then tighten the through-bolt flange nuts to specifications. www.mymowerparts.com 3-182 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD515 CD797A 10. Connect the temperature sensor wire to the main wiring harness. 11. Secure the wires to the frame with nylon ties. 12. Connect the speed sensor connector to the housing. 13. Secure the positive cable to the starter motor. 14. Secure all wiring to the frame and upper engine bracket with cable ties. CD793 8. Secure the engine ground wire to the engine with a cap screw. Tighten to specifications. 15. Secure the two coolant/oil hoses to the engine. 16. Secure the crankcase vent hose to the air cleaner housing; then secure the inlet boot and carburetor to the air cleaner housing. CD810 9. Connect the gear position indicator connector (A), stator connector (B), and the CDI connector (C) to the main wiring harness. CD787 CD785 www.mymowerparts.com 3-183 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 17. Secure the shift rod to the engine with a new E-clip. 19. Install the front body panel with existing hardware (see Section 8). 20. Connect the hose to the fuel pump; then connect the vacuum hose and secure with hose clamps. CD774 18. Place the left-side footwell and foot peg in position on the frame; then secure with existing hardware. Tighten to specifications. CD766A 21. Place the side panels into position; then install the reinstallable rivets. 22. Place the battery into position in the battery compartment; then install the battery cables and vent hose. Secure with the battery cover. ! CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. CD782 23. Add proper amounts of engine/transmission oil and coolant. 24. Install the seat. www.mymowerparts.com 3-184 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (500 - Manual Transmission) Removing Engine Transmission.......................... 3-185 Top-Side Components......................................... 3-189 Removing Top-Side Components ....................... 3-189 Left-Side Components ........................................ 3-193 Removing Left-Side Components ....................... 3-193 Right-Side Components ...................................... 3-198 Removing Right-Side Components..................... 3-198 Center Crankcase Components.......................... 3-202 Separating Crankcase Halves............................. 3-202 Disassembling Crankcase Half ........................... 3-204 Servicing Components........................................ 3-206 Assembling Crankcase Half ................................ 3-232 Joining Crankcase Halves................................... 3-235 Installing Right-Side Components....................... 3-236 Installing Left-Side Components ......................... 3-240 Installing Top-Side Components ......................... 3-245 Installing Engine/Transmission............................ 3-251 Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. ! CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 3. Remove the radiator access cover, steering post cover, and storage compartment cover assembly; then remove the storage compartment box. 4. Remove the reinstallable rivets securing the side panels; then remove the panels. 3 CD683A 5. Remove the instrument pod; then remove the front rack and front body panel (see Section 8). 6. Drain the oil from beneath the engine/transmission; then drain the cooling system. AT THIS POINT If the technician’s objective is to service/replace left-side cover oil seals (3), front output joint oil seal (1), rear output joint oil seal (1), and/or the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame. Secure the ATV on a support stand to elevate the wheels. ATV-0109 ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 1. Remove the seat. 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery vent hose; then remove the battery. CD799A www.mymowerparts.com 7. Remove the air filter (see Section 2). 3-185 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the vacuum hose fuel-pump-to-carburetor hose. and the CD803 CD766A 9. Remove the cap screws securing the left-side foot peg and footwell to the footrest; then remove the footwell. 12. Remove the E-clip securing the shift rod to the engine shift arm; then allow the shift rod to swing forward and hang straight down from the shift lever. 13. Disconnect the speed sensor connector from the sensor housing. 14. Remove the four cap screws securing the rear output joint to the transmission and push the shaft away from the transmission. CD782 10. Remove the springs securing the muffler to the exhaust pipe; then remove the muffler. Account for two exhaust springs. CD805 15. Loosen the clamp securing the air intake duct to the air filter housing. CF138A 11. Remove the cap screws securing the exhaust pipe to the head; then remove the exhaust pipe. CD785 16. Disconnect the crankcase vent hose from the air filter housing. Loosen the clamp securing the carburetor intake duct to the air filter housing; then remove the housing. www.mymowerparts.com 3-186 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD787 AR600D 3 CD786 AR604D 17. Remove the clamp securing the upper coolant hose to the thermostat housing; then disconnect the hose. 20. Remove the clamp securing the lower coolant hose to the water pump housing; then disconnect the hose. CC335D CC334D 18. Disconnect the high tension lead from the spark plug; then remove the coil. 21. Loosen the clamp on the crankcase breather vent hose; then remove the hose. 19. Disconnect the battery ground (negative) cable from the crankcase cover; then disconnect the positive cable from the starter motor. www.mymowerparts.com CC122D 3-187 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 22. Remove the engine/transmission mounting fasteners in the following sequence: A. Lower front: One cap screw, nut, spacer, and washer. CD812A CC123D B. Lower rear: One cap screw, nut, spacer, and washer. CD813 25. Remove the block and lower the rear of the engine; then remove the boot clamp on the front output drive yoke. CC126D 23. Raise the rear of the engine enough to allow the rear output flange to clear the output flange joint. Place a block beneath the engine in this position. CD817 26. Move the engine to the rear enough to allow the front drive coupler to clear the front output yoke; then move the engine forward and to the left. Remove the engine from the left-side of the frame. CD811 24. Remove the first small boot clamp; then slide the output flange and driveshaft out of the rear coupler. www.mymowerparts.com 3-188 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC001D CD773 Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. NOTE: Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated. 2. Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the cylinder head plug. Note the location of two alignment pins. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to removed from the frame for this procedure. CD205 Removing Top-Side Components A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspection plug; then using the recoil starter, rotate the crankshaft to top-dead-center of the compression stroke. 1. Remove the two tappet covers. CD468 NOTE: Note that the opening of the head plug must be directed to the 6 o’clock position. 3. Loosen the cap screw on the end of the tensioner; then remove the two Allen-head cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket. www.mymowerparts.com 3-189 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft. While holding the chain, slide the sprocket and camshaft out of the cylinder head. CC009D CC013D CC010D CC266D NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. 6. Remove the cap screw securing the chain tensioner (account for a washer); then remove the tensioner. CC011D 4. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. NOTE: Care should be taken not to drop the C-ring down into the crankcase. CC014D 7. Remove the five nuts securing the cylinder head to the cylinder; then remove the four cylinder head cap screws with copper washers (note location of the different-sized cap screws and nuts). www.mymowerparts.com 3-190 CC012D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. 9. Remove the cam chain guide. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC017D 3 CC022D CC018D C. Cylinder D. Piston NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. 10. Loosen the clamp securing the coolant hose to the union; then detach the hose. 11. Remove the two nuts securing the cylinder to the crankcase. CC016D 8. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. CC023D 12. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. CC020D www.mymowerparts.com 3-191 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC024D CC032D 14. Using the Piston Pin Puller (p/n 0644-328), remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side circlip prior to using the puller. CC025D CC033D NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder (p/n 0444-006). ! CAUTION CC026D AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section. ! CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston. 13. Using an awl, remove one piston-pin circlip. www.mymowerparts.com 3-192 Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation. When replacing with new rings, replace as a complete set only. If the piston rings must be removed, remove them in this sequence. A. Starting with the top ring, slide one end of the ring out of the ring-groove. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT To service piston, see Components sub-section. Servicing Top-Side AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. CC039D Left-Side Components 2. Remove the flange nut securing the starter cup to the crankshaft; then remove the starter cup. Account for the O-ring inside the cup. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. 3 AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. CC041D 3. Put the shift lever into the hi-range position and remove the circlip from the hi/low range shift shaft; then remove the shift lever. NOTE: It will be necessary to lift slightly on the shift lever to remove it from the shaft and plate. Removing Left-Side Components A. Recoil Starter B. Hi/Low Shifter Assembly C. Speed Sensor Housing D. Cover 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the recoil starter. CC044D AT THIS POINT To service the recoil starter, see Servicing Left-Side Components sub-section. www.mymowerparts.com 3-193 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC045D 4. Remove the inside circlip. CC054D 7. Remove the cap screws securing the left-side cover to the crankcase and note the location of the long cap screw with rubber washer. CC046D 5. Remove the two cap screws securing the speed sensor housing; then remove the housing. Account for the gasket. CC047D CF037A CD069 6. Remove the shift stop housing assembly from beneath the shift shaft housing. Account for the stopper and spring. www.mymowerparts.com 3-194 8. Using Side Case Puller (p/n 0644-262), remove the side cover. Account for a gasket, two alignment pins, and an idle gear limiter bushing. NOTE: Inspect the inside of the left-side cover for the four shaft washers that may have come off with the cover. The three gear shaft washers are identical and interchangeable. The shift shaft washer is a larger diameter. Keep the washers with their respective shafts for installing purposes. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD134A CD136 E. Rotor/Flywheel F. Idle Gear Assembly NOTE: Steps 1-8 in the preceding sub-section must precede this procedure. NOTE: For steps 9-18, refer to illustration CD134B. 3 CD138 10. Remove the idle gear (C), washer, and spacer from the countershaft. KEY A. Output Shaft with Driven Gear B. Drive Gears #1 & #2 C. Idle Gear D. Shift Fork with Shaft E. Shift Shaft Assembly F. Starter Gear Assembly G. Starter Idler Gear H. Starter Clutch Gear Assembly I. Rotor/Flywheel CD134B NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 9. Remove the starter gear assembly (F) from the crankcase; then remove the starter idler gear (G) and spacer. CD141 11. Remove the #2 drive gear (B), washer, and the select sliding dog gear from the driveshaft. Account for a bushing and a washer. AT THIS POINT To service shift fork, see Servicing Left-Side Components sub-section. 12. Remove the shift fork shaft (D) from the crankcase boss; then remove the shift fork from the shaft. Remove the shift shaft assembly (E) from the fixed shaft. Account for the left shaft washer. www.mymowerparts.com 3-195 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD146 CD154A 14. Remove the washer and driven gear (A) from the output shaft; then account for the bushing. CD147 CD149 CD152 13. Remove the circlip and washer from the driveshaft; then remove the #1 drive gear (B). Account for a splined bushing and a spacer. CC059D www.mymowerparts.com 3-196 CD150 15. Remove the Allen-head screws securing the shift-indicator sending unit; then remove the sending unit. Account for an O-ring, two contacts, and two springs. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD159 CD549 16. Remove the two cap screws securing the starter to the crankcase; then remove the starter. Account for the wiring forms. 18. Using Magneto Rotor Remover (p/n 0444-075), remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly (H) and thrust washer. 3 CC065D 17. Remove the nut securing the rotor/flywheel (I) to the crankshaft; then install the magneto rotor remover adapter. CD550 CD155 CD562 AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. www.mymowerparts.com 3-197 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT CF066A To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. 4. Remove the cap screw securing the impeller to the impeller shaft; then remove the impeller. Account for the rubber retainer and porcelain seal. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components A. Oil Filter B. Water Pump 1. Remove the clamp securing the coolant hose to the water pump; then remove the hose. CC029D 2. Using the adjustable Oil Filter Wrench (p/n 0644-389), remove the oil filter. 3. Remove the three cap screws securing the water pump cover to the right-side cover; then remove the water pump cover. Account for the O-ring. CD163A 5. Remove the fifteen cap screws securing the right-side cover to the crankcase. Remove the cover. Note the location of the long cap screw and rubber washer. Account for the gasket and for two alignment pins. CC027D www.mymowerparts.com 3-198 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC034D NOTE: The water pump housing does not have to be removed when removing the right-side cover. CD168A C. Primary Drive Clutch Shoe D. Primary Driven Clutch E. Primary Drive Clutch Housing NOTE: Steps 1-6 in the preceding sub-section must precede this procedure. 7. Remove the reverse cam stopper housing and gasket and account for a stopper and spring. CD164A NOTE: When removing the right-side cover, account for the release roller guide that it does not fall and cause damage. CC069D 8. Remove the clutch release arm and washer; then in a crisscross pattern, remove the four cap screws securing the clutch release roller assembly. CC070D 6. Remove the water pump drive joint from the water pump shaft. Account for the pin. CD171 www.mymowerparts.com 3-199 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Using the Clutch Sleeve Hub Holder (p/n 0444-007) to hold the clutch sleeve hub, remove the nut and washer. CC074D 9. Remove the release plate. Account for four springs. 10. Remove the primary drive clutch-shoe nut (left-hand threads) and washer from the driveshaft; then using a primary clutch shoe remover, remove the clutch shoe. CC076D 13. Scribe a line across the primary driven clutch assembly to aid in assembling. ! CAUTION Care must be taken when removing the nut; it has “left-hand” threads. CC077D 14. Simultaneously, remove the primary driven clutch assembly and primary drive clutch housing from their respective shafts. Account for the sleeve and washers. CC072D 11. Remove the primary drive one-way clutch from the primary drive clutch housing. Note the word OUTSIDE stamped on the clutch for installing purposes. CC078D AT THIS POINT To service clutch components, see Servicing Right-Side Components sub-section. CF043 www.mymowerparts.com 3-200 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 F. Gear Shift Cam Plate/Guide G. Oil Pump/Oil Strainer NOTE: Steps 1-14 in the preceding sub-sections must precede this procedure. 15. Remove the cam chain from the crankcase. 16. Remove the nut and washer securing the oil pump drive gear to the crank balancer shaft; then remove the gear and account for the pin and the spacer. CC086D 19. Remove the cap screw securing the gear shift cam plate and guide to the gear shift cam; then remove the cam plate and guide. 3 CC080D CC164D ! CAUTION If servicing of the engine/transmission is due to a lubrication-related problem, replace the oil pump. CF070A 17. Remove the gear shift shaft from the crankcase. NOTE: For general servicing, it is advisable to disassemble, clean, and inspect the oil pump. If any wear or damage is suspected, replace the oil pump. 20. Remove the circlip securing the oil pump driven gear; then remove the gear. Account for the pin and the washer. CC085D 18. Release the tension from the gear shift cam stopper arm spring. CC088D www.mymowerparts.com 3-201 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC089D 21. Remove the three Phillips-head screws securing the oil pump; then remove the oil pump. NOTE: It may be necessary to use an impact driver to loosen the screws. CC163D AT THIS POINT To service center crankcase components only, proceed to Separating Crankcase Halves. Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. CD190 22. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the O-ring. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves 1. Remove the five right-side 6 mm cap screws (one from inside the case) securing the crankcase halves. Note the location of the different-lengthed cap screws. CC091D 23. Remove the two Phillips-head cap screws securing the strainer. www.mymowerparts.com 3-202 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC530D CC098D 2. Remove the seven left-side 6 mm cap screws securing the crankcase halves. Note the location of the wiring form. Note the location of the different-lengthed cap screws. 5. Using the Crankcase Separator/Crankshaft Remover (p/n 0444-009) and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins, an O-ring, and a washer. NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. CC096D 3. Remove the three left-side 8 mm cap screws (two from inside the case) securing the crankcase halves. Note the location of the different-lengthed cap screws. CC099D CC097D 4. Remove the three right-side 8 mm cap screws securing the crankcase halves. CD227 www.mymowerparts.com 3-203 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF078A KEY A. Crank Balancer Assembly B. Crankshaft C. Balancer Drive Gear with Pin D. Countershaft Assembly E. Shift Shaft with Fork F. Gear Shift Cam G. Reverse Shift Cam H. Shift Shaft with Three Forks I. Driveshaft Assembly J. Output Shaft K. Reverse Idle Gear CC803C 1. Remove the two shift shafts (E and H). 2. Remove the reverse shift cam (G) and spacer. CC102D 3. Disengage four forks from the gear shift cam (F); then remove the reverse shifter fork. Disassembling Crankcase Half NOTE: For steps 1-10, refer to illustration CC803C. NOTE: To aid in assembling, it is recommended that the assemblies are kept together and IN ORDER. CC105D 4. Remove the gear shift cam (F). CC106D 5. Remove the three remaining forks noting their positions for assembling purposes. www.mymowerparts.com 3-204 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT To service gear shift forks, see Servicing Center Crankcase Components sub-section. 6. Remove the reverse idle gear (K) w/shaft. Account for the bushing, two washers, and the circlip. 7. Simultaneously, remove the driveshaft assembly (I) and countershaft assembly (D). Account for the washer on the countershaft. CD832 10. Remove the crank balancer assembly (A). AT THIS POINT To service the driveshaft and/or countershaft, see Servicing Center Crankcase Components sub-section. NOTE: For efficiency, if the driveshaft and/or countershaft are not being serviced, it is preferable to leave them assembled. The technician should use discretion and sound judgment. 3 8. Remove the front output shaft (J) and rear shaft assemblies. Account for the bearing C-ring. NOTE: Note the alignment marks on the crank balancer driven gear and balancer drive gear to aid in assembly. CD832B NOTE: There is a flat spot on the crank balancer to allow clearance past the crankshaft. 11. Using the Crankcase Separator/Crankshaft Remover (p/n 0444-009), push the crankshaft assembly out of the crankcase. CD826 9. Remove the driven gear from the crank balancer assembly (A). Account for a key. CC115D AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. ! CAUTION www.mymowerparts.com Do not remove the remaining output shaft assembly unless absolutely necessary. If the shaft is removed, the shaft nut must be replaced with a new one and the shaft must be re-shimmed. 3-205 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. To remove the output shaft and gear, remove the nut, slide the gear off the shaft (account for a shim or shims), and drive the shaft out with a plastic mallet (account for a shim or shims). Servicing Top-Side Components NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. CC482D NOTE: Whenever a valve is out of tolerance, it must be replaced. Cleaning/Inspecting Valve Cover Table of Contents (Servicing Components) NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. NOTE: Critical engine/transmission specifications are located at the beginning of this section. Servicing Top-Side Components......................... 3-206 Valve Assembly................................................ 3-206 Piston Assembly .............................................. 3-209 Cylinder/Cylinder Head Assembly ................... 3-211 Servicing Left-Side Components ........................ 3-214 Recoil Starter ................................................... 3-214 Measuring Shift Fork (Thickness) .................... 3-217 Measuring Shift Fork Groove (Width) .............. 3-218 Measuring Shift Fork To Groove (Side Clearance)........................................... 3-218 Servicing Right-Side Components ...................... 3-218 Primary Clutch Assembly................................. 3-218 Inspecting Oil Pump......................................... 3-221 Servicing Center Crankcase Components.......... 3-221 Secondary Gears............................................. 3-221 Crankshaft Assembly ....................................... 3-222 Driveshaft......................................................... 3-224 Countershaft .................................................... 3-230 2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover. CC130D www.mymowerparts.com 3-206 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. Removing Valves NOTE: Keep all valves and valve components as a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation. 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer. CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks (p/n 0644-022); then check the valve stem runout using a dial indicator. CC132D 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ATV-1082 2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. CC134D 2. Acceptable diameter range (intake valve) must be within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. www.mymowerparts.com 3-207 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1004 CC131D 2. Acceptable width range must be within specifications. 3. Push the valve from side to side; then from top to bottom. Measuring Valve Face Radial Runout 4. Maximum “wobble” deflection must not exceed specifications. 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 2. Acceptable inside diameter range must be within specifications. 3. If a valve guide is out of tolerance, it must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing. ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator. ! CAUTION If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur. Measuring Rocker Arm (Inside Diameter) 1. Using a dial calipers, measure the inside diameter of the rocker arm. 2. Acceptable inside diameter range must be within specifications. Measuring Rocker Arm Shaft (Outside Diameter) www.mymowerparts.com 3-208 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Acceptable outside diameter range must be within specifications. Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC132D PISTON ASSEMBLY NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. Cleaning/Inspecting Piston CC144D 2. Insert each valve into its original valve location. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head. NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston. 4. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. ATV-1011A 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters. CC400D www.mymowerparts.com 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. 3-209 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Cleaning/Inspecting Piston Rings 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. ! CAUTION Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston. ATV-1070 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within specifications. ATV-1069 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. 2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. CC280D Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within specifications, the piston pin must be replaced. Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. www.mymowerparts.com 3-210 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained. ATV-1085B 2. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration). ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. NOTE: The chrome (silver) ring should be installed in the top position. 3 CC128D 726-306A ! CAUTION Incorrect installation of the piston rings will result in engine damage. Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. CYLINDER/CYLINDER HEAD ASSEMBLY 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. NOTE: If the cylinder/cylinder head assembly cannot be trued, they must be replaced. 3. Maximum distortion must not exceed specifications. Cleaning/Inspecting Cylinder Head ! CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. CC141D www.mymowerparts.com 3-211 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. CC127D 2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a ball hone. NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder. CC129D Inspecting Cam Chain Guide 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 2. If the chain guide is damaged, it must be replaced. Honing Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications. www.mymowerparts.com 3-212 CC390D 4. If any measurement exceeds specifications, replace the cylinder. Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced. 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC283D CC005D 2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height. 3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely. NOTE: Do not rotate the camshaft when measuring clearance. 4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. ATV1013A 2. The lobe heights must not exceed minimum specifications. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. CC003D 5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance. Measuring Camshaft to Cylinder Head Clearance 1. Remove the adjuster screws and jam nuts. CC145D www.mymowerparts.com 6. If clearance is excessive, measure the journals of the camshaft. 3-213 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC287D NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head. Inspecting Camshaft Automatic Decompression Spring/Unloader Assembly 1. Inspect the spring, weights, and unloader for damage and freedom of movement. CF060A 2. If damaged, the camshaft must be replaced. Servicing Left-Side Components RECOIL STARTER KEY 1. Recoil Starter Assy 2. Reel 3. Spiral Spring 4. Ratchet Assy 5. Ratchet 6. Ratchet Guide 7. Nut 8. Rope Assy 9. Cap Screw 10. Starter Cup 11. Nut 0737-034 CF061A NOTE: With the weight extended, the unloader flat should be even with the camshaft journal. ! WARNING Always wear safety glasses when servicing the recoil starter. Removing/Disassembling 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the starter. CF061 NOTE: When the weight is released, the spring should return the assembly to the “unload” position with the unloader extending above the camshaft journal. www.mymowerparts.com 3-214 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case; then remove the ratchet guide from the friction plate. CC039D ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. B602D 5. Remove the spring cover, spring, and shaft. 2. Rotate the reel counterclockwise until the notch of the reel is near the rope guide in the case. Guide the rope into the notch and slowly allow the reel to retract until all spiral spring tension is released. 3 B603D 6. Remove the ratchet and account for the pin. B600D ! CAUTION During the disassembly procedure, make sure all spring tension is released before continuing. 3. Remove the nut. B604D 7. Carefully lift the reel from the case making sure the spring does not accidentally disengage from the case. B601D www.mymowerparts.com 3-215 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling/Installing 1. If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a counterclockwise direction until the complete spring is installed. NOTE: The spiral spring must seat evenly in the recoil case. B605D ! WARNING Care must be taken when lifting the recoil free of the case. Wear safety glasses to avoid injury. 8. Remove the protective cover from the starter handle and pull the rope out of the handle; then untie the knot in the rope and remove the handle. NOTE: Do not remove the spiral spring unless replacement is necessary. It should be visually inspected in place to save time. If replacement is necessary, follow steps 9-10. 9. Remove the spiral spring from the case by lifting the spring end up and out. Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case. 10. Unwind the rope from the reel and remove the rope. Cleaning and Inspecting NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. B606D 2. Insert the rope through the hole in the reel and tie a knot in the end; then wrap the rope counterclockwise around the reel leaving approximately 50 cm (20 in.) of rope free of the reel. 3. Apply low-temperature grease to the spring and hub. 4. Thread the end of the rope through the guide hole of the case; then thread the rope through the handle and secure it with a double knot. Install the protective cover into the handle. 5. Align the inner hook of the spiral spring with the notch in the reel. 1. Clean all components. 2. Inspect the springs and ratchet for wear or damage. 3. Inspect the reel and case for cracks or damage. 4. Inspect the shaft for wear, cracks, or damage. 5. Inspect the rope for breaks or fraying. B605D 6. Inspect the spiral spring for cracks, crystallization, or abnormal bends. 7. Inspect the handle for damage, cracks, or deterioration. www.mymowerparts.com 3-216 6. Install the ratchet onto its spring making sure the end is properly installed on the reel. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B604D 7. Install the shaft, spring, and the spring cover. B601D 10. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch of the reel. 11. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract. 12. Pull the rope out two or three times to check for correct tension. NOTE: Increasing the rotations in step 11 will increase spring tension. B603D 8. Install the friction plate with the ratchet guide fitting into the ratchet. 13. Place the recoil starter assembly into position on the left-side cover; then tighten the cap screws to specifications. CC039D B602D 9. While pushing down on the reel, install the nut. Tighten securely. MEASURING SHIFT FORK (Thickness) NOTE: Whenever a shift fork is out of tolerance, replacement is necessary. 1. Using a calipers, in turn measure the thickness of the machined tip of each shift fork. www.mymowerparts.com 3-217 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Shift fork to groove side clearance must be within specifications. Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. CC296D 2. Shift fork thickness must be within specifications. MEASURING SHIFT FORK GROOVE (Width) 1. Using a calipers, in turn measure the width of each shift fork groove. PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring/Assembling) NOTE: Prior to inspecting and measuring components, it is recommended that all components be removed from the primary gear assembly and be cleaned. NOTE: When removing components from the primary gear assembly, account for the bushing that fits into the primary gear. CC288D 2. Shift fork groove width must be within specifications. CC239D MEASURING SHIFT FORK TO GROOVE (Side Clearance) Inspecting/Measuring Clutch Driven Plate Warpage 1. In turn, insert each shift fork into its groove. 2. Using a feeler gauge, measure the clearance between the shift fork and the groove. 1. Inspect each driven plate for warpage and burn marks. 2. In turn place each driven plate on the surface plate; then using a feeler gauge, measure warpage in several locations. CC292D www.mymowerparts.com 3-218 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC245D 3. Maximum driven plate warpage must not exceed specifications. Measuring Clutch Drive Plate (Fiber) Thickness 1. Using a calipers, in turn measure the thickness of each drive plate in several locations. ATV1014 Inspecting Centrifugal Clutch Housing 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. Inspecting Primary One-Way Drive 1. Insert the drive into the centrifugal clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. 3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. Assembling Primary Clutch CC243D 2. Drive plate thickness must be within minimum specifications. 3. If the fiber plate tabs are damaged, the plate must be replaced. 4. Inspect the clutch sleeve hub for grooves or notches. If grooves or notches are present, replace the hub. KEY 1. 2. 3. 4. 5. 6. 7. Pressure Disc Driven Plate Drive Plate Sleeve Hub Primary Gear Assy Washer Washer Inspecting Centrifugal Clutch Shoe 1. Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. 2. Inspect the depth of the grooves in the clutch shoes. If any shoe is worn to the bottom of the groove, replace the complete set. 737-731A 1. Place the clutch hub upside down into the primary gear assembly. ! CAUTION Always replace clutch shoes as a complete set or severe imbalance could occur. www.mymowerparts.com 3-219 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC920 CF047A 2. Alternately install the drive plates and driven plates onto the hub (starting with and ending with a drive plate) making sure the tabs with the notches are all in line with each other. 4. Place the primary gear assembly w/clutch hub assembly in one hand, place the other hand on top of the clutch hub assembly, and flip the assembly over; then lift the primary gear assembly off the clutch hub assembly being careful not to disturb the drive plate notched tab orientation. CF044A NOTE: When installing the driven plates for ease of installation, make sure they are placed onto the hub with the rounded side of the plates directed down. CC924 5. Place the primary gear assembly on a clean, flat surface; then install the primary washer into the assembly. CF045A 3. Install the pressure plate onto the hub making sure the alignment dots are correctly positioned. www.mymowerparts.com 3-220 CC239D 6. Place the clutch hub assembly into the primary gear assembly. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY GEARS CC926 ! CAUTION The clutch hub and the pressure plate must be seated in the proper position. If any of the incorrect positions are used, the hub and plate will have clearance between them and they will not operate properly. NOTE: The primary clutch assembly is now completely assembled for installation. INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur. Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft. 2. Install the secondary driven output shaft assembly onto the crankcase. 3. Mount the indicator tip of the dial indicator on the secondary driven bevel gear. 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary. CD989A 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim. 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. www.mymowerparts.com 3-221 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Backlash Measurement Shim Correction Under 0.05 mm (0.002 in.) Decrease Shim Thickness At 0.05-0.33 mm (0.002-0.013 in.) No Correction Required Over 0.33 mm (0.013 in.) Increase Shim Thickness Checking Tooth Contact NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. 2. Clean the secondary driven bevel gear teeth of old oil and grease residue. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. 4. Install the secondary driven output shaft assembly. ATV-0104 Correcting Tooth Contact NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary. If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart. Tooth Contact Shim Correction Contacts at Top Decrease Shim Thickness 5. Rotate the secondary driven bevel gear several revolutions in both directions. Contacts at Root Increase Shim Thickness 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations. NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted. ! CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures until they are both within tolerance values. CRANKSHAFT ASSEMBLY ATV-0103 Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. ATV-0105 www.mymowerparts.com 3-222 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. 2. Acceptable width range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. CC290D 2. Maximum diameter must not exceed specifications. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 3 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. ATV-1074 3. Zero the indicator and rotate the crankshaft slowly. ! CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications. NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 2-4. Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. CC289D 3. Acceptable gap range must be within specifications. www.mymowerparts.com 3-223 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1017 CC226D 2. Acceptable width range must be within specifications. DRIVESHAFT Disassembling 1. In order, remove the reverse dog, circlip, washer, reverse driven gear, and bushing from the driveshaft. CC225D CC228D CC224D NOTE: The teeth on the bushing must face the 1st driven gear. 2. Remove the 1st driven washer (right side); then remove the 1st driven gear from the driveshaft. CC227D www.mymowerparts.com 3-224 CC223D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the 4th driven gear from the driveshaft. Note the four small dogs facing toward the 3rd driven gear for assembling purposes. CC222D 3. Remove the 1st driven bushing; then remove the 1st driven washer (left side) from the shoulder of the splined shaft. Remove the 4th driven circlip. CC219D 5. Remove the 3rd driven circlip; then remove the 3rd driven lock washer (right side) from the driveshaft. 3 CC221D CC216D CC220D CC215D 6. Remove the 3rd driven gear from the driveshaft. CC508D www.mymowerparts.com 3-225 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC214D CC211D 7. Remove the 3rd driven bushing from the driveshaft. Note the location of the oil feed hole in the bushing and the matching oil supply hole in the driveshaft for assembling purposes. 10. Remove the 5th driven gear from the driveshaft. CC210D 11. In order, remove the 2nd driven circlip, washer, gear, and bushing from the driveshaft. CD248 8. Remove the 3rd driven lock washer (left side) from the driveshaft. Note the tabs facing toward the 5th driven gear for assembling purposes. CC209D CD247A 9. Remove the next 3rd driven lock washer (left side) by rotating it out of the groove. Note the groove closest to the 5th driven gear for assembling purposes. CC208D www.mymowerparts.com 3-226 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. In order, install the 2nd driven bushing, gear, washer, and circlip onto the driveshaft. CC207D CC206D 3 CC206D AT THIS POINT To service secondary gears, see Servicing Center Crankcase Components in this sub-section. CC207D Assembling CC208D KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Driveshaft 1st Driven Gear 2nd Driven Gear 3rd Driven Gear 3rd Driven Bushing 4th Driven Gear 5th Driven Gear Reverse Driven Gear Reverse Dog Reverse Driven Bushing 3rd Driven Lock Washer Right 12. 3rd Driven Lock Washer Left 13. 3rd Driven Lock Washer Left 14. Driveshaft Bearing 15. 1st Driven Bushing 16. 2nd Driven Bushing 17. 2nd Driven Circlip 18. 3rd Driven Circlip 19. 4th Driven Circlip 20. Reverse Driven Washer 21. 1st Driven Washer - Left 22. 1st Driven Washer - Right 23. 2nd Driven Washer 24. Reverse Driven Circlip CC209D 2. Install the 5th driven gear onto the driveshaft. 737-733A www.mymowerparts.com 3-227 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC210D 3. Install the 3rd driven lock washer (left side). Lock it into the groove closest to the 5th driven gear (as noted in disassembling) by rotating it when it is in the groove. CD248 ! CAUTION It is very important to assure the oil feed hole in the bushing and oil supply hole in the driveshaft align. If not aligned, engine damage will result. 6. In order, install the 3rd driven gear, lock washer (right side), and circlip onto the driveshaft. CC211D 4. Install the next 3rd driven lock washer (left side) onto the driveshaft making sure the tabs are facing toward the 5th driven gear. Make sure the tabs intertwine with the 3rd driven lock washer. CC214D CC215D CD247A 5. Install the 3rd driven bushing onto the driveshaft making sure the oil feed hole in the bushing aligns with the appropriate oil supply hole in the driveshaft (as noted in disassembling). www.mymowerparts.com 3-228 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC216D CC220D 7. Install the 4th driven gear onto the driveshaft making sure the four small dogs are facing toward the 3rd driven gear as noted in disassembling; then secure with the circlip. 3 CC221D CC219D CC222D 9. Install the 1st driven washer (right side) on the shaft making sure it lines up with the groove in the shaft; then turn the washer locking it on the shaft. CC508D 8. Install the 1st driven washer (left side) onto the shoulder of the splined shaft; then install the 1st driven bushing and gear. CC223D www.mymowerparts.com 3-229 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Slide the reverse driven gear bushing onto the shaft making sure the oil port in the bushing aligns with the oil port on the shaft. CC226D CC842 ! CAUTION Failure to align the oil ports will result in serious engine damage. 11. Move the washer in the shaft groove until the notches in the washer align with the tabs on the bushing; then slide the bushing up tight against the washer. CC227D CC843 12. In order, install the reverse driven gear, washer, circlip, and reverse dog onto the driveshaft. CC228D NOTE: The driveshaft is now completely assembled for installation. COUNTERSHAFT Disassembling 1. Remove the 2nd drive gear and washer from the countershaft. CC225D www.mymowerparts.com 3-230 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the 4th drive circlip securing the 4th drive gear on the countershaft; then remove the first 4th drive washer and 4th drive gear. Account for the bushing. CD242 2. Remove the 5th drive gear from the countershaft. CC199D 6. Remove the other 4th drive washer from the countershaft. 3 Assembling CC203D 3. Remove the 5th drive washer and 5th drive circlip from the countershaft. KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. CC201D Countershaft 2nd Drive Gear 3rd Drive Gear 4th Drive Gear 5th Drive Gear 5th Drive Washer 5th Drive Bushing Shaft Bearing 4th Drive Bushing 4th Drive Circlip 11. 12. 13. 14. 15. 16. 17. 18. 19. 5th Drive Circlip Shaft Bearing Retainer 4th Drive Washer Washer Reverse Idle Shaft Reverse Idle Gear Reverse Idle Bushing Screw 738-294A 1. Install the 4th drive washer onto the countershaft. 2. Install the 4th drive gear making sure the bushing is in position; then install the other 4th drive washer onto the countershaft. Secure with the circlip. CC200D 4. Remove the 3rd drive gear from the countershaft. www.mymowerparts.com 3-231 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC199D 3. Install the 3rd drive gear; then install the 5th drive circlip onto the countershaft. CD242 NOTE: The countershaft is now completely assembled for installation. Assembling Crankcase Half NOTE: For ease of assembly, install components on the left-side crankcase half. CC200D 4. Install the 5th drive washer and 5th drive gear onto the countershaft. NOTE: If the output shaft and gear were removed, make sure that the proper shim is installed. 1. To install the output shaft and gear, place the shaft into position with proper shims, slide the gear onto the shaft, and secure with a new nut tightened to specifications. CC201D 5. Install the 2nd drive gear and washer onto the countershaft. www.mymowerparts.com 3-232 CC117D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC116D CD832A 2. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. 4. With the key in position, slide the driven gear onto the crank balancer making sure the timing marks are aligned. 3 CD826 CC688 5. Place the bearing C-ring into position in the crankcase; then install the front output shaft and rear shaft assemblies. ! CAUTION The bearing pins must be positioned into the crankcase correctly or damage to the crankcase may occur. CC689 NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool. 3. Install the crank balancer. NOTE: It will be necessary to rotate the crank balancer until the counterweight is directed away from the crankshaft; then rotate the crankshaft clockwise into the journal area to allow the balancer to be fully seated. CD268A 6. Simultaneously, install the driveshaft and countershaft assemblies making sure the washer is on the countershaft. www.mymowerparts.com 3-233 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD232A CC107D 7. Install the reverse idle shaft with circlip making sure the oil hole in the shaft is facing downward; then install a washer, bushing, reverse idle gear, and a washer. CC106D 9. Engage the four forks to the gear shift cam; then install the reverse shift cam and spacer. CF055 CC105D CC231D 8. Place each of the four shift forks into its respective gear or dog as noted during disassembling; then install the gear shift cam. CC103D 10. Install the two gear shift shafts; then verify that the two crankcase half alignment pins are in place. www.mymowerparts.com 3-234 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC104D NOTE: Prior to joining crankcase halves, turn the shift cam to ensure all gears shift properly. CC098D 4. From the right side, install the three case half 8 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. Joining Crankcase Halves 3 1. Place the O-ring in the left-side crankcase half and verify that the washer is on the idler shaft; then apply Three Bond Sealant to the mating surfaces. Place the right-side half onto the left-side half. CC097D 5. From the left side, install the seven case half 6 mm cap screws noting the location of the wiring form; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. CC234DA 2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 3. From the left side, install the three case half 8 mm cap screws (two inside the case); then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. CC096D 6. From the right side, install the five case half 6 mm cap screws (one inside the case); then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. www.mymowerparts.com 3-235 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the strainer cap into position on the strainer making sure a new O-ring is properly installed and secure with the cap screws; then install and tighten the oil drain plug to specifications. CC095D 7. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws (from steps 3-4) until the halves are correctly joined; then tighten to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 8. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws (from steps 5-6) to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. CC091D 3. Place the oil pump into position in the crankcase and secure with the three Phillips-head screws coated with blue Loctite #243. Tighten to specifications. ! CAUTION After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to In- stalling Top-Side Components. Installing Right-Side Components A. Oil Strainer/Oil Pump B. Gear Shift Shaft CC090D 4. Place the pin and washer into position on the oil pump shaft, install the oil pump driven gear, and secure with the circlip. 1. Place the oil strainer into position beneath the crankcase and tighten securely with the Phillips-head cap screws. CC088D www.mymowerparts.com 3-236 CC163D 5. Place the gear shift cam plate and guide onto the gear shift cam making sure the alignment pin was installed. Secure assembly with the cap screw coated with blue Loctite #243. Tighten securely. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF073A CC085D C. Primary Driven Gear D. Primary Driven Clutch E. Primary Drive Clutch Shoe NOTE: Steps 1-7 in the preceding sub-section must precede this procedure. CC164D 8. Install the spacer, pin, and oil pump drive gear onto the crank balancer shaft making sure the shoulder of the drive gear is facing inward toward the crankcase; then secure with the washer and nut tightened to specifications. 6. Attach the spring to the gear shift cam stopper arm. CF070A CC086D CD481 CF072A 7. Install the gear shift shaft. 9. Place the chain into the crankcase; then secure it from the top side with a wire for ease of assembling. www.mymowerparts.com 3-237 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Using the Clutch Sleeve Hub Holder (p/n 0444-007), install the nut and washer. Tighten to specifications. CC079D 10. Install the primary driven washers onto the driveshaft and crankshaft. CD479 13. Place the primary drive one-way clutch into the starter clutch housing noting the word OUTSIDE for proper placement. CD198B ! CAUTION The clutch sleeve hub and the pressure plate must be seated in the proper position. If any of the incorrect positions are used, the hub and plate will have clearance between them and they will not operate properly. 11. Simultaneously, place the primary clutch assembly and the starter clutch housing on their respective shafts making sure the sleeve is properly positioned in the primary assembly. CD482 14. Install the clutch shoe and washer; then secure with the starter clutch shoe nut (left-hand threads). Tighten to specifications; then using a center punch, stake the nut. 15. Install the release roller assembly making sure the four springs are in position; then using a crisscross pattern, tighten the four cap screws securely. NOTE: Tighten the four roller assembly cap screws in a crisscross pattern making sure there is no clearance between the clutch plates when secured. CC078D NOTE: Note the alignment mark scribed on the primary driven gear assembly during disassembly. www.mymowerparts.com 3-238 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC074D 16. Install the clutch release arm and release roller guide making sure the release roller and guide are aligned. CD494 F. Water Pump G. Oil Filter NOTE: Steps 1-18 of the preceding sub-sections must precede this procedure. NOTE: Lubricate all internal components with 5W-30 oil prior to installing the right-side cover. 19. Place the water pump drive joint into position on the water pump shaft making sure the pin is properly positioned. CD166A 17. Secure the clutch release arm with the cap screw coated with blue Loctite #243. Tighten securely. CF067 NOTE: Care should be taken that the alignment pins are installed in the right-side cover. CC073D 18. Install the reverse cam stopper housing and gasket making sure the stopper and spring are correctly positioned. Tighten to specifications. 20. Place the gasket and right-side cover into position making sure the release roller guide remains correctly positioned and that the water pump drive adapter aligns; then install the fifteen cap screws. Note the proper location of the long cap screw with rubber washer. www.mymowerparts.com 3-239 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF039A CC067D 21. Tighten the cap screws in a crisscross pattern to specifications. 24. Install the coolant hose on the water pump and secure with the clamp. 22. Place the water pump cover onto the right-side cover making sure the new O-ring is properly positioned. Tighten securely with the three cap screws. Installing Left-Side Components A. Idle Gear Assembly B. Magneto Rotor 1. Place the starter into position on the crankcase and secure with the cap screws. Note the position of the wiring form. CD910A CC065D CC027D 23. Using the oil filter wrench, install a new oil filter. www.mymowerparts.com 3-240 2. Place the shift-indicator sending unit into position making sure the contacts and springs are inside the case and a well-oiled O-ring is properly positioned. Secure with Phillips-head screws. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the spacer onto the driveshaft. CC049D CC258D 6. Place the splined bushing onto the driveshaft making sure the oil hole of the splined bushing aligns with the oil hole of the driveshaft. ! CAUTION It is important that the oil holes in the splined bushing and driveshaft align. If they are not aligned, major damage will occur from lack of lubrication. CC048D 3. Install the starter idle gear pin into the crankcase; then with the beveled side of the idle gear facing the crankcase, install the idle gear and spacer. CF038A 7. In turn on the driveshaft, install the #1 drive gear and washer; then secure with the circlip. CD138 4. Place the bushing onto the output shaft; then install the driven gear and washer. CC059D 8. Place the select sliding dog gear and washer onto the driveshaft; then place the #2 drive gear onto the driveshaft making sure the bushing and washer follow on the driveshaft. www.mymowerparts.com CC063D 3-241 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. With the slot in the shift shaft assembly facing upward, place the assembly on the fixed shaft. CC061D 9. Place the idle gear spacer and idle gear onto the countershaft. CD147 12. Place the left shaft washer on the shift shaft. CC262D CC333D 13. With the shift fork peg positioned in the shift shaft assembly slot, install the shift fork in the select sliding dog gear. CC060D 10. Place a washer on the driveshaft, the countershaft, and the driven shaft. CC329D 14. Slide the shift fork shaft through the shift fork and into the crankcase boss. CF075A www.mymowerparts.com 3-242 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC330D CD444 15. Insert the pin into the starter gear assembly boss in the crankcase; then install starter idler gear #1. 19. Install the two alignment pins into the left crankcase half. NOTE: Make sure that four washers, one bushing, and two alignment pins are in place. 3 CD136 16. Place a washer on each end of the starter gear assembly and install in the crankcase. 17. Place a thrust washer onto the crankshaft; then install the starter clutch gear assembly onto the crankshaft. Place the key into its notch. CD134A C. Cover D. Speed Sensor Housing E. Hi/Low Shifter Assembly F. Recoil Starter NOTE: Steps 1-19 in the preceding sub-section must precede this procedure. 20. Place the gasket and left-side cover into position on the crankcase. NOTE: It may be necessary to push or pull the splined Hi/Low range shift shaft to establish cover/crankcase mating. CD155 18. Place the rotor/flywheel into position on the crankshaft; then install the nut on the crankshaft and tighten until the rotor/flywheel is properly seated. Tighten to specifications. 21. Install the fourteen cap screws to secure the left-side cover. Do not tighten at this time. Note the location of the long cap screw with rubber washer. www.mymowerparts.com 3-243 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF037A CC054D 22. Place the starter cup into position on the crankshaft making sure a new, lubricated O-ring is inside the cup. Tighten the flange nut to specifications. 25. Place the speed sensor housing and gasket into position and secure with the two cap screws. Tighten securely. CD069 CC041D 23. In a crisscross pattern, tighten the cap screws (from step 21) to specifications. 26. Install the inside circlip onto the hi/low range shift shaft with the sharp side of the circlip facing the engine; then place the shift lever assembly part way onto the shaft. NOTE: Position the shift lever part way onto the splines and verify the subtransmission is in hi range. If not, shift into hi range. CC047D 24. Place the shift stop housing assembly into position beneath the shift shaft housing making sure the spring and stopper are correctly positioned. Tighten to specifications. CC045D www.mymowerparts.com 3-244 27. Pull up on the hi/low shift T-handle and guide the T-handle stop pin into the hi range lever stop plate slot; then slide the shift lever assembly the rest of the way onto the shift shaft. Secure with the outer circlip making sure the sharp side of the circlip faces away from the hi/low-range lever. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. CC044D 28. Place the recoil starter assembly into position on the left-side cover; then tighten four cap screws to specifications. ATV-1085B B. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. CC039D Installing Top-Side Components ATV-1024 C. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration). A. Piston B. Cylinder KEY 1. 2. 3. 4. 5. 6. 7. 8. NOTE: The chrome (silver) ring should be installed in the top position. Cylinder Stud Bolt Nut Cylinder Gasket Pin Water Hose Union Cap Screw O-Ring ! CAUTION Incorrect installation of the piston rings will result in engine damage. 1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip faces upwards. 0732-301 NOTE: If the piston rings were removed, install them in this sequence. NOTE: The piston should be installed so the arrow points toward the exhaust. www.mymowerparts.com 3-245 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Loosely install the two nuts which secure the cylinder to the crankcase. NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10. CC032D 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. CC023D 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover CC025D 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase. ! CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Cylinder Head Assy Valve Guide Dowel Pin Cap Screw Cap Screw Cylinder Head Gasket Dowel Pin Cap Screw Cap Screw Stud Bolt Stud Bolt Stud Bolt Cap Screw Cap Screw Nut Nut Gasket 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Head Nut Gasket Spark Plug Inspection Cap O-Ring Cap Screw Stud Bolt Cylinder Head Plug Intake Pipe Assy O-Ring Cap Screw Clamp Water Temperature Switch Assy 30. Thermostat Cover 31. Thermostat *Frost Plug *Not Illustrated 0737-755 NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. CC024D www.mymowerparts.com 3-246 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Place the chain guide into the cylinder. ! CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. CC272D 9. Loosely install the five cylinder head nuts. CC022D 3 7. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder. CC018D CC020D CC017D 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) to 3.8 kg-m (27.5 ft-lb); then tighten the 8 mm nut (from step 9) to 2.5 kg-m (18 ft-lb). Using a crisscross pattern, tighten the four 6 mm nuts (from step 9) to 1.1 kg-m (8 ft-lb). Tighten the two cylinder-tocrankcase nuts (from step 4) securely. CF057A 8. Install the four cylinder head cap screws with copper washers (note the locations of the different-lengthed cap screws). Tighten only until snug. 11. With the timing inspection plug removed and the chain held tight, rotate the crankshaft until the piston is at top-dead-center. 12. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat” the sprocket onto the shaft. www.mymowerparts.com 3-247 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following. 732-307B NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. 13. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket. CD463 A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. ! CAUTION CC015D NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft is necessary for alignment, do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position. If any of the above factors are not as stated, go back to step 11 and carefully proceed. 15. Place the tab-washer onto the sprocket making sure it covers the pin in the alignment hole. ATV-1027 ! CAUTION CF030A www.mymowerparts.com 3-248 Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF013A CC012D 16. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug. 20. Install the cylinder head plug in the cylinder head with the opening of the plug directed downward and toward the inside. 3 CD468 CD464 17. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) and tighten to specifications. Bend the tab to secure the cap screw. 21. Place the cam chain tensioner guide into position and secure with the cap screw and washer. CC014D 22. Remove the cap screw from the end of the chain tensioner; then using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner clockwise until the screw bottoms. CD465 18. Rotate the crankshaft until the first cap screw (from step 16) securing the sprocket to the camshaft can be addressed; then tighten to specifications. Bend the tab to secure the cap screw. 19. Place the C-ring into position in its groove in the cylinder. www.mymowerparts.com 3-249 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD501 CD470 NOTE: The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 24. 23. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two Allen-head cap screws. CD471 25. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover. 26. Apply a thin coat of Three Bond Sealant (p/n 0636-070) to the mating surfaces of the cylinder head and valve cover. CD469 CC275D CC010D 24. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until all tension is released; then install the cap screw into the end of the chain tensioner. www.mymowerparts.com 3-250 27. Place the valve cover into position. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 28. Install the four top side valve cover cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 F. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. 31. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. CC003D 29. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 28) securely. 30. Adjust valve/tappet clearance using the following procedure. NOTE: Use Valve Clearance 0444-078) for this procedure. Adjuster (p/n A. Turn the engine over until the piston reaches top dead center on the compression stroke. B. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. CC001D 32. If removed, install the spark plug and tighten to specifications. Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame; then move it rearward as far as possible. 2. Raise the rear of the engine enough to engage the front driveshaft into the splines of the front drive output yoke; then slide the engine forward as far as possible. CC528D C. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. D. Align the valve adjuster handle with one of the marks on the valve adjuster dial. E. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until specified valve/tappet clearance is attained. CD818 NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark. www.mymowerparts.com 3. Raise the rear of the engine and place a block under it; then install the propeller shaft and output flange into the rear drive coupler. 3-251 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC124D CD821 4. Remove the block from beneath the engine; then align the rear drive flanges and secure with four cap screws. Tighten to specifications. 8. Connect the positive cable to the starter motor and install the protective boot. AR604D CD824 9. Connect the battery ground (negative) cable to the crankcase cover. 5. Install the lower rear engine mounting through-bolt, spacer, and washer; then install the lower front engine mounting through-bolt, spacer, and washer. Secure with the flange nuts. Tighten to specifications. AR600D 10. Install the coil and secure with two cap screws; then install the high tension lead on the spark plug. CD809 6. Connect the crankcase breather vent hose and secure with the clamp. 7. Connect the lower coolant hose to the water pump housing and secure with the clamp. www.mymowerparts.com 3-252 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Position the carburetor into the intake pipe and secure with the clamp; then connect the carburetor boot to the air filter housing. Secure with the clamp. CD814 11. Connect the upper coolant hose to the thermostat housing and secure with the clamp. CD790 3 CC121D 12. Install the air filter housing; then connect the crankcase breather and the inlet air duct. Secure with the clamps. CD786 14. Connect the speed sensor connector to the sensor housing. CD785 CD794 15. Install the exhaust pipe and secure with two cap screws making sure the mounting brackets engage the frame grommets; then install the muffler with the springs. Tighten all hardware to specifications. www.mymowerparts.com CD787 3-253 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF138A CD766A 19. Connect the temperature sensor wire to the main harness. CD803 16. Swing the shift rod back into position on the engine shift arm; then secure with the E-clip. CD788 17. Place the left-side footwell and foot peg into position on the footrest. Secure with two cap screws. Tighten to specifications. 20. Connect the gear position indicator connector (A), stator connector (B), and the CDI connector (C) to the main harness. CD782 CD797A 18. Connect the gas hose to the fuel pump; then connect the vacuum hose. Secure with hose clamps. 21. Install the front body panel and the front rack (see Section 8). 22. Place the side panels into position; then install the reinstallable rivets. www.mymowerparts.com 3-254 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 25. Pour 2.9 L (3 U.S. qt) of premixed Arctic Cat Antifreeze into the cooling system. Allow coolant to settle and then fill to the bottom of the stand pipe in the radiator neck. 26. Install the seat making sure it locks into position. ! CAUTION CD683A 23. Install the battery connecting the positive cable first; then the negative cable. If the engine had a major overhaul or if any major part was replaced, proper engine break-in procedures must be followed (see Section 1). If the proper engine break-in procedures are not followed, severe engine damage may result. 24. Pour the correct amount of recommended oil into the engine/transmission filler hole; install the filler plug. 3 ATV-0108 www.mymowerparts.com 3-255 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (700 EFI) Removing Engine/Transmission ......................... 3-256 Top-Side Components......................................... 3-260 Removing Top-Side Components ....................... 3-260 Left-Side Components ........................................ 3-264 Removing Left-Side Components ....................... 3-264 Right-Side Components ...................................... 3-268 Removing Right-Side Components..................... 3-268 Center Crankcase Components ......................... 3-271 Separating Crankcase Halves............................. 3-271 Disassembling Crankcase Half ........................... 3-272 Servicing Components........................................ 3-274 Assembling Crankcase Half ................................ 3-294 Joining Crankcase Halves................................... 3-296 Installing Right-Side Components....................... 3-297 Installing Left-Side Components ......................... 3-299 Installing Top-Side Components ......................... 3-303 Installing Engine/Transmission............................ 3-307 CF237A 5. Remove the front rack and front body panel (see Section 8). 6. Drain the oil from beneath the engine/transmission; then drain the coolant. Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. FI005A AT THIS POINT If the technician’s objective is to service/replace left-side components, right-side components, and/or top-side components, the engine/transmission does not have to be removed from the frame. 1. Remove the seat. 2. Remove the negative cable from the battery; then remove the positive cable. 3. Remove the radiator access cover, steering post cover, and storage compartment cover assembly; then remove the storage compartment box. 4. Remove the side panels. www.mymowerparts.com 3-256 FI004A 7. Remove the air filter (see Section 2). 8. Disconnect the primary coil wire; then disconnect the ground wire and remove the high tension wire/spark plug cap from the spark plug. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the clamp securing the cooling duct boot to the V-belt housing; then remove the cooling duct boot from the V-belt housing outlet. FI066A 9. Loosen the clamp securing the air inlet duct to the air filter housing. FI075 3 FI098A 10. Disconnect the crankcase vent hose from the air filter housing; then loosen the clamp securing the air filter housing to the throttle body. FI076 12. Remove the left-side foot peg and footwell (see Section 8). 13. Disconnect the air intake temperature sensor connector; then lift the air filter housing off the frame and slip the air pressure sensor off the mount. Remove the air filter housing. FI081A FI082A 14. Remove the ISC valve connector, the TPS connector, the coolant temperature sensor connector, and the fuel injector connector. www.mymowerparts.com FI099A 3-257 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI089A 15. Remove the springs securing the muffler to the exhaust pipe. Account for the two exhaust springs. FI079 NOTE: It is advisable to lock the brake when loosening the cap screws securing the rear driveshaft. 19. Remove the positive cable from the starter motor and route it out of the way. FI097A 16. Remove the two flange nuts securing the exhaust pipe to the cylinder head; then remove the pipe. FI094 20. Disconnect the speed sensor connector from the sensor housing; then mark the shift arm/shift shaft for installating purposes and remove the shift arm. FI073 17. Remove the two coolant hoses from the engine; then route the hoses out of the way. 18. Remove the cap screws securing the rear driveshaft/output flange to the rear output joint flange. www.mymowerparts.com 3-258 FI078A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Make sure the ignition switch is in the OFF position and the FUEL fuse is removed from the PDM to prevent inadvertent discharge of gas from the gasline hose. FI085A 21. On the left side, disconnect the gear position indicator connector (A), stator connector (B), and the crankshaft position sensor connector (C). FI109A 23. Loosen the clamp securing the throttle body to the intake pipe; then remove the throttle body and secure it out of the way. 24. Remove the two cap screws securing the intake pipe to the cylinder head and remove the intake pipe. Account for an O-ring. ! CAUTION FI083A 22. Using an absorbent towel to catch any spilled gas, press the locking tab release on the gasline hose connector; then slide the gasline hose connector off the fuel rail. ! WARNING Whenever working on the fuel system if a gasline hose is removed from any component, slowly bleed the pressure from the hose into an absorbent towel before removing the hose from the component. Cover the intake opening to prevent hardware or dirt from entering the intake or severe engine damage could occur. 25. Remove the engine damper stopper from the frame; then remove the engine damper mount and damper from the engine. NOTE: The engine damper mount is secured to the engine with the thermostat housing cap screws. Note the position of the bleed valve in the thermostat for assembling purposes. 3TOPPER $AMPER FI092A $AMPER -OUNT FI067A 26. Support the engine/transmission; then remove the lower front through-bolt. www.mymowerparts.com 3-259 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 27. Remove the lower rear through-bolt; then free the engine from the engine mounting brackets. 1. Remove the cylinder head cover. Account for a gasket and four seal washers. 28. Lift the front of the engine/transmission far enough to disengage the front drive spline from the engine; then remove the engine from the left-side of the ATV. FI122 2. Check and record valve tappet clearance for reference when assembling (see Section 2). FI102 Top-Side Components 3. Remove the eight cap screws securing the camshaft holders to the cylinder head. 4. Install two alignment studs in the exhaust camshaft holder; then carefully remove the cam shaft holder. Account for two alignment pins. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. FI125A NOTE: The engine/transmission does not have to removed from the frame for this procedure. Removing Top-Side Components A. Cylinder Head Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspection plug; then using the recoil starter, rotate the crankshaft to top-dead-center of the compression stroke. Account for a copper washer on the timing inspection plug. www.mymowerparts.com 3-260 FI123A NOTE: Alignment studs can be made by cutting the heads off two 6 mm x 5 cm cap screws and will aid in preventing loss of the alignment pins into the crankcase. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI155A FI055 5. Remove the exhaust camshaft; then repeat step 4 for the intake camshaft. Account for two alignment pins. 3 FI056 FI124A 6. Remove the intake camshaft; then wipe the four valve tappets clean and using a suitable marker, number the tappets and mark the corresponding position on the cylinder head. NOTE: The adjustment shims are of different thickness. Whenever the shims are removed, they must remain with the corresponding valve tappets or complete valve adjustment will be required when assembling. NOTE: This will greatly simplify valve clearance adjustment during assembling. FI157 8. Remove the cam chain tensioner plug, spring, guide pin, and O-ring; then remove the cam chain tensioner body. FI154 7. Using a magnet, withdraw the valve tappets from the cylinder head taking care to prevent loose adjusting shims from falling into the engine. www.mymowerparts.com 3-261 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI159A FI162A 9. Remove the coolant bypass hose from the cylinder head fitting; then remove the coolant crossover hose. FI131A ! CAUTION FI160 Failure to hold the cam chain idler shim against the cam chain idler shaft may result in the shim falling into the engine resulting in severe engine damage. 11. Remove the cam chain idler from the cam chain; then support the cam chain to prevent it from dropping into the crankcase. FI161 10. Loosen but do not remove the cam chain idler shaft; then using a suitable flat-blade screwdriver, hold the cam chain idler shaft shim against the shoulder of the cam chain idler shaft and remove the shaft. Account for a copper seal washer and the cam chain idler shim. FI163 ! CAUTION Do not rotate the engine with the cam chain loose or severe engine damage could occur. 12. Remove the cylinder head cap screws (four 6 mm and five 12 mm) noting the location of the longer and shorter 6 mm cap screws; then remove the cylinder head. Account for two alignment pins and one head gasket. www.mymowerparts.com 3-262 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. FI133A FI136A AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section. ! CAUTION FI134A AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. When removing the cylinder, make sure to support the piston to prevent damage to the crankcase and piston. 15. Note the position of the orientation dot on the piston; then remove the piston pin circlips using care not to drop the circlip into the crankcase. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. C. Cylinder D. Piston NOTE: Steps 1-12 in the preceding sub-section must precede this procedure. 13. Remove the cam chain guide; then remove the two nuts from the cylinder base mounting studs. FI138A FI139 www.mymowerparts.com FI135A 16. Remove the piston pin and the piston. 3-263 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The piston pin is a full-floating type and should slide out by hand. If the piston pin is stuck, use Piston Pin Puller (p/n 0644-328) to remove the piston pin. Left-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. CC033D NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder (p/n 0444-006). ! CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation. When replacing with new rings, replace as a complete set only. If the piston rings must be removed, remove them in this sequence. A. Starting with the top ring, slide one end of the ring out of the ring-groove. B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT To service piston, see Components sub-section. Servicing Top-Side NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Left-Side Components A. Recoil Starter B. Water Pump C. Cover D. Rotor/Flywheel E. Oil Pump 1. Remove the four cap screws securing the recoil starter assembly to the left-side cover; then remove the recoil starter. Account for the gasket. AT THIS POINT To service the recoil starter, see Servicing Left-Side Components sub-section. 2. Remove the flange nut securing the starter cup to the crankshaft; then remove the starter cup. Account for the O-ring inside the cup. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. www.mymowerparts.com 3-264 CD925A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the three cap screws securing the water pump to the engine; then remove the water pump. FI185A 5. Remove the starter torque limiter. Account for two washers, one bushing, and the shaft. FI141A AT THIS POINT To service the water pump, see Section 4. 3 4. Remove the cap screws securing the left-side cover to the crankcase noting the location of the engine ground cap screw for installing purposes; then remove the left-side cover. Account for a gasket and two alignment pins. FI189 6. Remove the starter idler shaft (1) and the starter idler gear (2); then remove the shift shaft (3). Account for two washers on the shift shaft. FI147A FI148A FI184A NOTE: Inspect the inside of the left-side cover for any shaft washers that may have come off with the cover. Make sure they are returned to their respective shafts. www.mymowerparts.com FI302 3-265 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the shift cam driven gear (4); then remove the cam stopper (5). Account for a spring. 9. Remove the rotor/flywheel nut (6); then install the flywheel protector (7) and Magneto Rotor Remover (p/n 0444-206) (8) and remove the rotor/flywheel. Note the orientation of the one-way bearing. FI311A FI184B FI307A 8. Remove the circlip securing the drive gear on the countershaft; then remove the drive gear. Account for a spacer. FI191A FI192A FI310 www.mymowerparts.com 3-266 FI309A FI195A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Make sure the crankshaft protector is fully installed on the crankshaft and the rotor/flywheel puller is turned all the way onto the rotor/flywheel or severe damage to the crankshaft, rotor/flywheel, or puller will occur. 10. Remove the rotor/flywheel key; then remove the starter driven gear. FI200A 3 FI193A FI201A 13. Using an impact driver and appropriate Phillips-head bit, remove the three cap screws securing the oil pump and remove the oil pump. FI194 11. Remove the pivot bolt from the cam chain tensioner; then remove the cam chain tensioner and cam chain. Account for a washer. FI308 NOTE: The oil pump is not a serviceable component. Do not disassemble the oil pump. It is available only as a complete assembly. 14. Remove the cap screws from the crankshaft balancers; then remove the crankshaft balancer driven gears. Account for two washers and two keys. FI197A 12. Remove the snap ring (1) from the oil pump shaft; then remove the oil pump driven gear (2) and drive chain (3). Account for the oil pump drive pin (4) and washer (5). www.mymowerparts.com 3-267 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT FI303A 15. Using a 52 mm deep-well socket and a suitable holding tool, remove the crankshaft balancer drive gear nut (1) from the crankshaft; then remove the drive gear (2). Account for a washer (3) and drive pin (4). To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover FI305A 1. Remove the cap screws securing the V-belt cover; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Account for a gasket. 2. Remove the bearing cap; then using Spanner Wrench (p/n 0444-153) to hold the drive pulley, remove the cap screw from the clutch shaft. FI318A FI316A 3. Remove the three cap screws securing the V-belt bearing housing to the inner V-belt cover; then remove the housing. Account for two dowel pins and a spacer. www.mymowerparts.com 3-268 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI315 FI313 6. Remove the fixed drive face and center bushing. 7. Remove the eleven cap screws securing the inner V-belt cover to the clutch cover; then remove the inner V-belt cover. Account for two gaskets. 3 FI429A 4. Make match marks on the fixed drive face and the movable drive face; then remove the movable drive face. FI225A FI334 5. Using Spanner Wrench (p/n 0444-153) to hold the driven pulley, remove the cap screw from the driveshaft; then remove the driven pulley assembly and the V-belt. FI226 NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 8. Remove the gear shift switch. Account for two springs and two gear shift switch contacts. www.mymowerparts.com 3-269 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI319 FI271A 11. Using a hydraulic press or rubber mallet, remove the centrifugal clutch housing from the clutch cover. Account for the primary shaft spacer with O-ring. FI280 9. Remove the twelve cap screws securing the clutch cover to the engine case noting the positions of the two longer cap screws; then remove the clutch cover. Account for two alignment pins and a gasket. FI344 12. Using Spanner Wrench (p/n 0444-153) to hold the centrifugal clutch assembly, remove the clutch retainer nut (left-hand threads); then remove the centrifugal clutch assembly from the crankshaft. Account for a concave washer and note that the concave side is directed toward the clutch assembly. FI272 10. Note the reference mark and the word OUTSIDE stamped on the cage of the one-way clutch; then remove the one-way clutch. FI279A www.mymowerparts.com 3-270 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI336 FI274 13. Remove the oil jet from the crankcase. Account for an O-ring. 3 FI275 FI337 Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. FI276 NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves 1. Remove the thirteen right-side 6 mm cap screws using a crisscross pattern; then remove the six right-side 8 mm cap screws. Note the location of the different-lengthed cap screws and the wire clip location. FI277 2. Using the Crankcase Separator/Crankshaft Remover (p/n 0444-009) and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. www.mymowerparts.com 3-271 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. FI288A 2. Remove the reverse idler gear assembly (F). Account for two washers, shaft, needle bearing, and the gear. FI273 Disassembling Crankcase Half NOTE: For steps 1-7, refer to illustration FI235A. FI291 3. Remove the shift fork shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes. KEY A. Secondary Driven Shaft Assembly B. Crank Balancer Assembly C. Crankshaft D. Countershaft Assembly E. Driveshaft F. Reverse Idler Gear Assembly G. Gear Shift Camshaft H. Shift Fork Shaft with Two Forks FI235A NOTE: To aid in assembling, it is recommended that the assemblies are kept together and IN ORDER. 1. Remove the secondary driven shaft assembly (A) noting the location of the bearing locating pin (1). Account for the bearing C-ring (2). www.mymowerparts.com 3-272 FI282A 4. Remove the gear shift camshaft (G) noting the location of the two holes on the end of the shaft. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI282B 5. Remove the countershaft assembly (D). Account for a washer on the end of the countershaft. FI407 ! CAUTION Do not attempt to separate the output driven gear from the output driveshaft. They are serviced as an assembly only. 8. Remove the front and rear crankshaft balancers; then install the magneto cover on the left crankcase half. 9. Using Crankcase Separator/Crankshaft Remover (p/n 0444-009), remove the crankshaft assembly from the bearing; then remove the magneto cover. FI343 NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. 6. Using a small chisel or screwdriver, unlock the drive bevel gear nut; then hold the output driven gear with a suitable holding tool and remove the drive bevel gear nut. FI252 FI349 7. Using a rubber mallet, tap the output driveshaft from the bearing. Account for a shim, driven bevel gear, washer, and nut. www.mymowerparts.com 3-273 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (Servicing Components) NOTE: Critical engine/transmission specifications are located at the beginning of this section. Servicing Top-Side Components ........................ 3-274 Cylinder Head/Valve Assembly ....................... 3-274 Piston Assembly ............................................. 3-277 Cylinder Assembly ........................................... 3-278 Servicing Left-Side Components ....................... 3-281 Recoil Starter .................................................. 3-281 Inspecting Oil Pump ........................................ 3-284 Servicing Right-Side Components ..................... 3-284 Inspecting Centrifugal Clutch Shoe ................ 3-284 Inspecting Clutch Housing .............................. 3-284 Inspecting Primary One-Way Drive ................. 3-285 Driven Pulley Assembly ................................... 3-285 Servicing Center Crankcase Components ......... 3-289 Secondary Gears ............................................ 3-289 Crankshaft Assembly ...................................... 3-290 Countershaft ................................................... 3-291 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. Servicing Top-Side Components NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. FI358 Measuring Cylinder Head Distortion CYLINDER HEAD/ VALVE ASSEMBLY 1. Remove any carbon buildup in the combustion chamber. When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. NOTE: Whenever a valve is out of tolerance, it must be replaced. 3. Maximum distortion must not exceed specifications. Cleaning/Inspecting Cylinder Head ! CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. FI357 www.mymowerparts.com 3-274 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Valves NOTE: Keep all valves and valve components as a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation. 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer. FI330 2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. FI331 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. 2. Acceptable diameter range (intake valve) must be within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a calipers, measure the width of the valve face. FI351 NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks (p/n 0644-022); then check the valve stem runout using a dial indicator. ATV-1004 2. Acceptable width range must be within specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator. www.mymowerparts.com 3-275 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing. ! CAUTION FI328 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Stem Deflection (Wobble Method) If any valve is discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind a valve or severe engine damage may occur. Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. 1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator. FI351 2. Insert each valve into its original valve location. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head. FI323 NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. 3. Push the valve from side to side; then from top to bottom. 4. Maximum “wobble” deflection must not exceed specifications. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 2. Acceptable inside diameter range must be within specifications. 3. If a valve guide is out of tolerance, it must be replaced. www.mymowerparts.com 3-276 ATV-1011A 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Cleaning/Inspecting Piston 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. FI331 PISTON ASSEMBLY 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. ! CAUTION NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. Cleaning/Inspecting Piston 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston. 3 Measuring Piston-Ring End Gap (Installed) 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 1. Place each compression ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within specifications. NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston. 4. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. FI327 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within specifications, the piston pin must be replaced. CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. www.mymowerparts.com 3-277 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Piston Rings Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. ATV-1070 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. ATV-1085B NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. NOTE: The chrome (L-shaped) ring must be installed in the top position. The ring marked RN must be installed in the middle position. ATV-1069 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. FI168A ! CAUTION Incorrect installation of the piston rings will result in engine damage. CYLINDER ASSEMBLY CC127D 2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. www.mymowerparts.com 3-278 NOTE: If the cylinder/cylinder head assembly cannot be trued, they must be replaced. Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained. ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. CC127D 2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, replace the cylinder. 4. If any measurement exceeds the limit, replace the cylinder and piston. Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced. CC129D Inspecting Cam Chain Guide 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 2. If the chain guide is damaged, it must be replaced. Honing Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications. CC283D 2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. www.mymowerparts.com 3-279 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height. FI444 5. If clearance is excessive, measure the journals of the camshaft. ATV1013A 2. The lobe heights must not exceed minimum specifications. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. FI377 Measuring Camshaft to Cylinder Head Clearance 1. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 2. Place the camshafts in the cylinder head; then install the camshaft journal caps and tighten. NOTE: Do not rotate the camshaft when measuring clearance. NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head. Inspecting Exhaust Camshaft Compression Release Assembly 1. Inspect the spring and decompression pin for damage. 3. Remove the camshaft journal caps; then remove the camshafts. 4. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head clearance. FI411 www.mymowerparts.com 3-280 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. 2. Rotate the reel counterclockwise until the notch of the reel is near the rope guide in the case. Guide the rope into the notch and slowly allow the reel to retract until all spiral spring tension is released. FI412 2. If damaged, the camshaft must be replaced. Servicing Left-Side Components 3 RECOIL STARTER KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Recoil Starter Assy Rope Assy Spiral Spring Reel Ratchet Assy Nut Cap Screw Nut Starter Cup O-Ring O-Ring Spacer Oil Seal Bearing B600D ! CAUTION During the disassembly procedure, make sure all spring tension is released before continuing. 3. Remove the nut. 0737-764 Removing/Disassembling 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the starter. B601D 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case; then remove the ratchet guide from the friction plate. CC039D www.mymowerparts.com 3-281 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B602D 5. Remove the spring, collar, and friction spring. B605D ! WARNING Care must be taken when lifting the reel free of the case. Wear safety glasses to avoid injury. 8. Remove the protective cover from the starter handle and pull the rope out of the handle; then untie the knot in the rope and remove the handle. NOTE: Do not remove the spiral spring unless replacement is necessary. It should be visually inspected in place to save time. If replacement is necessary, follow steps 9-10. B603D 6. Remove the ratchet and account for the pin. 9. Remove the spring from the case by lifting the spring end up and out. Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case. 10. Unwind the rope from the reel and remove the rope. Cleaning and Inspecting NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. B604D 7. Carefully lift the reel from the case making sure the spiral spring does not accidentally disengage from the case. 1. Clean all components. 2. Inspect the springs and ratchet for wear or damage. 3. Inspect the reel and case for cracks or damage. 4. Inspect the shaft for wear, cracks, or damage. 5. Inspect the rope for breaks or fraying. 6. Inspect the spiral spring for cracks, crystallization, or abnormal bends. 7. Inspect the handle for damage, cracks, or deterioration. www.mymowerparts.com 3-282 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling/Installing 1. If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a counterclockwise direction until the complete spring is installed. NOTE: The spiral spring must seat evenly in the recoil case. B604D 7. Install the friction spring and the spring cover. 3 B606D 2. Insert the rope through the hole in the reel and tie a knot in the end; then wrap the rope counterclockwise around the reel leaving approximately 50 cm (20 in.) of rope free of the reel. B603D 3. Apply low-temperature grease to the spring and hub. 8. Install the friction plate with the ratchet guide fitting into the ratchet. 4. Thread the end of the rope through the guide hole of the case; then thread the rope through the handle and secure it with a double knot. Install the protective cover into the handle. 5. Align the inner hook of the spiral spring with the notch in the reel. B602D 9. While pushing down on the reel, install the nut. Tighten securely. B605D 6. Install the ratchet making sure the end is properly installed on the reel. www.mymowerparts.com 3-283 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC446D B601D 10. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch of the reel. 11. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract. 12. Pull the rope out two or three times to check for correct tension. NOTE: Increasing the rotations in step 11 will increase spring tension. 13. Place the recoil starter assembly into position on the left-side cover; then tighten the cap screws to specifications. Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the complete set. ! CAUTION Always replace the clutch shoes as a complete set or severe imbalance could occur. CC039D INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. www.mymowerparts.com 3-284 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 3. Install the pilot bushing with the machined end directed down; then fit the bushing into the pulley hub. 1. Insert the drive into the clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. 3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. DRIVEN PULLEY ASSEMBLY Disassembling CD067 ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 4. Using a suitable marking pen, make alignment marks on the fixed face spring holder and both pulley faces. 1. Secure Driven Pulley Compressor (p/n 0444-121) in a suitable holding fixture such as a bench vise; then remove the wing nut, holding handle, flat washer, and pilot bushing leaving the large spacer on the compressor tool base. CD049 5. Place the holding handle on the spring holder fitting the two dowel pins into the spring holder face; then install a flat washer and the wing nut. Turn the wing nut down until resistance is felt. CD047 NOTE: Do not use the wing nut to compress the spring further. 2. Place the driven pulley assembly onto the compressor tool base engaging the dowel pins into appropriate holes in the fixed face of the assembly. CD050 www.mymowerparts.com CD048 3-285 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING The spring assembly is under pressure. Extreme care must be taken when relaxing the spring. Always wear safety glasses. Use proper tools only. 6. Using a spanner and suitable breaker bar, loosen the notched-ring nut; then spin the nut free of the hub. CD053 10. Using a thin pry-bar or screwdriver, work the movable face sleeve upward and free of the O-rings; then remove the sleeve. CD051 7. Firmly hold the handle and slowly turn the wing nut counterclockwise to relax the spring. NOTE: There will be a tendency for the handle to rotate clockwise approximately ¼ turn as the spring holder clears the flats or hub. This is due to a slight counterclockwise preload on the spring. CD054 11. Remove the four pins and spacers from the cam slots in the movable face; then remove the movable face. CD052 8. Release the preload slowly; then continue to relax the spring until the wing nut is flush with the end of the threads. 9. Firmly holding the spring and spring holder, remove the wing nut; then remove the spring. www.mymowerparts.com 3-286 CF091 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Make sure the spacer is on the base or damage to the fixed face will occur when the spring is compressed. CD056 Inspecting 1. Inspect the pulley faces for wear, galling, or grooving. 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. CD048 2. Apply multi-purpose grease to the O-rings and grease seals on the movable face; then install on the fixed face making sure the alignment marks are properly aligned. CF092A 3. Inspect two grease seals in the movable face for nicks, cuts, or damage. CD060 3. Install the four pins and spacers into the fixed face hub; then pack the cam slots in the movable face with multi-purpose grease. CF095A 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking. Assembling 1. Place the fixed face of the driven pulley on the pulley compressor base making sure the dowel pins are engaged in the appropriate holes in the pulley face. CF095A 4. Install the movable face sleeve aligning the hole in the spring seat with the spring anchor hole in the movable face. www.mymowerparts.com 3-287 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF097 CD052 5. Install the spring over the hub and movable face sleeve; then insert the end of the spring through the sleeve and into the spring anchor hole in the movable face. 8. Compress the spring until the spring holder nears the threads on the fixed face hub; then using the handle, wind the spring holder counterclockwise to align the flats of the spring holder and hub. CF089A 6. Place the spring holder on the spring engaging the spring end with the appropriate anchor hole. CD052A 9. Continue compressing the spring while guiding the spring holder onto the hub. When a slight resistance is felt, stop turning the wing nut. 10. Install the nut (threads coated with red Loctite #271); then tighten the nut to specification using the spanner and a torque wrench. CF087A 7. Assemble the notched-ring nut, spring holding handle, one flat washer, and the wing nut in order on the pulley compressor bolt; then thread the wing nut onto the bolt. CD066 11. Remove the wing nut, washer, and holding handle; then remove the driven pulley from the pulley compressor. www.mymowerparts.com 3-288 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY GEARS NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur. Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft. 2. Install the secondary driven output shaft assembly onto the crankcase. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary driven bevel gear. Backlash Measurement Shim Correction Under 0.03 mm (0.001 in.) Increase Shim Thickness At 0.03-0.15 mm (0.001-0.006 in.) No Correction Required Over 0.15 mm (0.006 in.) Decrease Shim Thickness Checking Tooth Contact NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. 2. Clean the secondary driven bevel gear teeth of old oil and grease residue. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. 4. Install the secondary driven output shaft assembly. 5. Rotate the secondary driven bevel gear several revolutions in both directions. 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations. 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.03-0.15 mm (0.001-0.006 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thicker shim. ATV-0103 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thinner shim. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. ATV-0105 www.mymowerparts.com 3-289 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-0104 Correcting Tooth Contact NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary. If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart. Tooth Contact Shim Correction Contacts at Top Increase Shim Thickness Contacts at Root Decrease Shim Thickness NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted. ! CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures until they are both within tolerance values. FI267 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. FI266 3. Maximum gap range must not exceed specifications. www.mymowerparts.com 3-290 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. 2. Acceptable width range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft. ATV-1017 2. Acceptable width range must be within specifications. COUNTERSHAFT ! CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction. In either case, complete disassembly and assembly will be required. ATV-1074 3. Zero the indicator and rotate the crankshaft slowly. ! CAUTION Disassembling 1. Remove the thrust washer (1); then remove the low driven gear (2) and the bushing (3) noting the orientation of the oil hole. Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications. NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 2-4. Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. FI391A 2. Remove the low/reverse spacer (4), low/reverse clutch dog (5), and reverse driven gear (6); then noting the orientation of the oil hole, remove the reverse driven gear bushing (7). www.mymowerparts.com 3-291 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the high driven gear spacer (10), high driven clutch dog (11), and the high driven gear (12). Account for the bushing (13), wave washer (14), and thrust washer (15). FI392A FI397A FI393A 3. Remove the locking tab washer (8); then rotate the thrust washer (9) and remove from the countershaft. FI399A Assembling 1. Install the thrust washer (15), wave washer (14), and bushing (13) on the countershaft; then install the high driven gear (12) making sure the wave washer (14) is aligned under the thrust washer (15). FI395A FI399A FI396A www.mymowerparts.com 3-292 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI398A FI395A 2. Install the high driven gear spacer (10) and high driven clutch dog (11). 4. Install the reverse driven gear bushing (7) making sure to align the oil hole in the bushing with the oil hole in the countershaft; then install the reverse driven gear (6), low/reverse clutch dog (5), and low/reverse spacer (4). 3 FI402A 3. Position the thrust washer (9) onto the countershaft; then while pressing toward the driven gear, rotate the thrust washer to engage the splines and install the locking tab washer (8) making sure the tabs engage the splines. FI393A FI392A FI396A 5. Install the low driven bushing (3) making sure the oil hole in the bushing aligns with the hole in the countershaft; then install the low driven gear (2) and the thrust washer (1). www.mymowerparts.com 3-293 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Apply red Loctite #271 to the threads of the output shaft; then secure with the nut. Tighten nut to specifications; then using a punch, peen the nut as shown. FI391A NOTE: The countershaft is now completely assembled and ready for installation. FI346A 3. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. FI406 NOTE: When installing the countershaft assembly, account for the washer on each end of the shaft. FI409 Assembling Crankcase Half 1. Install the output shaft assembly into the crankcase making sure the driven bevel gear, shim, washer, and nut are properly sequenced. FI407 www.mymowerparts.com 3-294 NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool. 4. Install the drive pin (4) in the crankshaft; then apply red Loctite #271 to the threads of the crankshaft and install the crankshaft balancer drive gear (2), washer (3), and nut (1). Tighten to specifications; then using a punch, stake the nut to the crankshaft. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the water pump drive gear on the front crankshaft balancer and the oil pump drive sprocket on the rear crankshaft balancer; then thread in but do not tighten the cap screws at this time. FI318A FI441A 7. Install the assembled countershaft; then install the driveshaft. FI305A 5. Install the front and rear crankshaft balancers; then install the drive keys and driven gears making sure the timing marks are properly aligned to the drive gear timing marks. FI343 8. Install the shift cam assembly making sure the two holes on the end of the shaft are positioned vertically. 9. Insert the two shift forks into the sliding dogs noting the direction of the tabs from disassembling; then install the gear shift fork shaft. FI303A NOTE: Make sure the shift fork tabs face upward and that they are properly seated into the shift cams. FI303B www.mymowerparts.com FI282A 3-295 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Install the reverse idler gear assembly noting the positioning of the two washers, gear, bushing, and shaft. Joining Crankcase Halves 1. Apply High-Temp Sealant to the left-side mating surface. 2. Lightly oil all bearings and grease all shafts in the right-side crankcase. 3. Making sure to align the shafts and alignment pins, join the two crankcase halves. ! CAUTION FI291 11. Install the rear secondary driven shaft assembly into the left side of the crankcase making sure the bearing locating pin (1) is facing upward and the bearing C-ring (2) is fully seated in the crankcase. Do not heat the bearing in the right-side crankcase half. Damage to the oil seal will occur. 4. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 5. From the right side, install the 8 mm cap screws (two inside the case); then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 6. From the right side, install the 6 mm cap screws (two inside the case); then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. FI288A 12. Place the oil strainer into position in the left crankcase half. 7. In a crisscross pattern, tighten the 8 mm cap screws (from step 5) until the halves are correctly joined; then tighten to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 8. In a crisscross pattern, tighten the 6 mm cap screws (from step 6) to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. FI299 13. Install the two alignment pins in the left crankcase half. www.mymowerparts.com 3-296 AT THIS POINT After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to In- stalling Top-Side Components. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Right-Side Components 1. Install the shift indicator sending unit making sure the two neutral contact pins and the two springs are properly positioned. Tighten the Allen-head screws securely. FI279A 4. Lightly grease the clutch housing seal; then insert the primary drive spacer. 3 FI281 2. Using a new O-ring, install the oil jet in the right side of the crankcase. FI344 FI337 3. Install the clutch shoe assembly and secure with the washer (with the flat side facing the assembly as noted in removing) and the nut (threads coated with red Loctite #271). Tighten to specifications. ! CAUTION Care must be taken that the directional washer be installed correctly and note that the nut has left-hand threads. FI420A 5. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase. 6. Apply grease to the outer edges of the clutch housing; then from inside the clutch cover, install the clutch housing into the cover using a rubber mallet. 7. Install the one-way clutch onto the clutch shoe assembly. ! CAUTION When installed correctly, the green dot (or the word OUTSIDE) on the one-way clutch is visible. www.mymowerparts.com 3-297 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Place the V-belt into position over the front shaft. FI442A 8. Place the clutch cover/clutch housing assembly into position on the crankcase; then secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten to specifications. 9. Position the two gaskets in place on the crankcase; then install the inner V-belt housing. FI221 NOTE: The arrows on the V-belt should point forward. 14. Pinch the V-belt together near its center and slide the movable drive face and clutch housing spacer onto the shaft. Secure the drive face with a cap screw (threads coated with red Loctite #271). Tighten the cap screw to specifications. FI226 FI429A ! CAUTION Make sure the splines extend beyond the movable drive face plate or the clutch housing spacer may become jammed when the cap screw is tightened. This could result in a false torque reading. FI225 10. Place the driven pulley assembly into position and secure with the nut. Tighten to specifications. 11. Slide the fixed drive face onto the shaft. 12. Spread the faces of the driven pulley by pushing the inner face toward the engine while turning it counterclockwise; then when the faces are separated, press the V-belt down between the pulley faces. www.mymowerparts.com 3-298 FI428A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 15. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. 16. Install the V-belt housing assembly and tighten the three cap screws securely. FI219 2. Install the drive pin in the oil pump shaft; then with the drive chain around both the drive sprocket and the driven sprocket, install the driven sprocket onto the oil pump engaging the drive pin. Secure with the circlip. FI220 17. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to specifications. NOTE: The sharp side of the circlip should be facing outward. Installing Left-Side Components 1. Install the oil pump securing it to the crankcase with three Phillips-head cap screws (threads coated with red Loctite #271). Tighten securely. FI426 FI421 FI200 3. Apply red Loctite #271 to the two crankshaft balancer cap screws and tighten to specifications. www.mymowerparts.com 3-299 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI432A FI311 4. Install the cam chain tensioner making sure the washer is in place. Tighten the shoulder-bolt to specifications. 7. Install the gear shift shaft with the index mark aligned with the index mark on the shift cam stopper plate. Make sure there is a washer on both ends of the gear shift shaft. FI197A 5. Install the shift cam stopper, spring, and washer. Tighten the cap screw securely making sure the stopper arm moves freely. FI427 FI302 FI307B 6. Install the shift cam stopper plate. Tighten securely. www.mymowerparts.com 3-300 8. Install the cam chain over the cam drive sprocket; then secure the chain out of the way to prevent it from falling into the crankcase. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI435 ! CAUTION Do not turn the engine with the cam chain loose or severe engine damage will occur. FI422 11. Clean any oil or grease from the crankshaft and rotor/flywheel and secure with the flange nut. Tighten to specifications. 9. Install the starter driven gear; then install the key in the crankshaft. 3 FI425 FI193A 10. Install the spacer on the driveshaft; then install the output drive gear and secure with the circlip. Make sure the flat side of the circlip is directed away from the gear. FI436 12. Install the starter idler gear and shaft; then with a washer on each side, install the starter torque limiter and bushings. FI430A www.mymowerparts.com 3-301 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Verify that the washers are properly located; then install the magneto cover and secure with the cap screws. Tighten only until snug. FI148 FI185A 15. Place the starter cup into position on the crankshaft making sure a new, lubricated O-ring is inside the cup. Tighten the flange nut to specifications. FI301 13. Install the two alignment pins (A) in the crankcase; then place the gasket in position. CD925A 16. Tighten the cap screws (from step 14) to specifications. 17. Place the speed sensor housing and new O-ring into position and secure with the cap screw. Tighten securely. FI176A NOTE: The use of alignment studs (B) will aid in the installation of the magneto cover. 18. Place the water pump into position and secure with three cap screws. Tighten securely. FI141A www.mymowerparts.com 3-302 FI438A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 19. Place the gasket and recoil starter assembly into position on the left-side cover; then tighten four cap screws to specifications. Installing Top-Side Components A. Piston B. Cylinder FI168A KEY 1. 2. 3. 4. 5. 6. 7. 8. ! CAUTION Cylinder Stud Bolt Nut Cylinder Gasket Pin Water Hose Union Cap Screw O-Ring Incorrect installation of the piston rings will result in engine damage. 1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip faces upwards. NOTE: The piston should be installed so the orientation dot is directed toward the exhaust. 0732-301 NOTE: If the piston rings were removed, install them in this sequence. A. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. FI138A 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. ATV-1085B NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. B. Install the middle ring (2) so the letters RN are directed toward the top of the piston; then install the top ring (1) with the lip directed toward the top of the piston. FI136A www.mymowerparts.com 3-303 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase. ! CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. 4. Loosely install the two nuts which secure the cylinder to the crankcase. FI443 7. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder. FI135A NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10. 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. FI134A 8. Install the five 10 mm cylinder head cap screws and tighten in the sequence shown to an initial torque of 2.5 kg-m (18 ft-lb); then using the same sequence, tighten to a final torque of 3.7 kg-m (27 ft-lb). NOTE: Apply engine oil to the threads and both sides of the washers before installing the cylinder head cap screws. 6. Place the chain guide into the cylinder. ! CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. FI133B 9. Install the four 6 mm flange-head cap screws and tighten to specifications. Tighten the cylinder-to-crankcase nuts (from step 4) securely. www.mymowerparts.com 3-304 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI133C FI131A 10. Align the TDC line on the rotor/flywheel with the index mark on the magneto cover; then install the camshaft idler into the cam chain and align the punch mark (1) with the index rib (2). Adjust the idler in the chain as necessary to align the marks. 12. Install the cam chain tensioner with a new gasket; then tighten the Allen-head cap screws to specifications. 13. Install the spring and spring guide pin into the cam chain tensioner; then with a new O-ring installed on the tensioner plug, install the plug and tighten to specifications. FI447A ! CAUTION FI159A When checking the alignment, place tension on the front of the chain by pulling up on the idler and rotating to the rear. The punch mark (1), index rib (2), and gear tooth root (3) must align or engine damage will occur. If all three cannot be aligned, remove the idler and rotate the crankshaft one turn (360°) and repeat step 10. 14. Install the proper tappet shims on the corresponding valves as noted during removing; then install the tappets as noted during removing. FI053 FI447B 11. When the idler gear is properly timed, place the seal washer and cam chain idler shim on the cam chain idler shaft; then install the shaft and tighten to specifications. www.mymowerparts.com 3-305 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 18. Rotate the engine through three or four revolutions; then rotate to top-dead-center (TDC) on the compression stroke and check valve adjustment (see Section 2). 19. With a new gasket installed on the cylinder head cover, apply Three Bond Sealant (p/n 0636-070) to the camshaft end caps; then place the head cover into position on the cylinder head. FI054 NOTE: The tappet shims must be installed with the numbers facing the tappet. 15. Oil the tappets, camshaft journals, and cylinder head journals with clean engine oil; then install the four camshaft holder alignment pins. 16. With the TDC line aligned with the index mark on the magneto cover, install the camshafts with the engraved marks parallel with the top of the cylinder head and the I and E directed toward the intake or exhaust side of the head. FI040A 20. Apply engine oil to the cylinder head cover seal washers; then install the cylinder head cover cap screws and seal washers. Tighten in a crisscross pattern to 1.0 kg-m (7 ft-lb). Repeat in the same pattern to a final torque of 1.4 kg-m (10 ft-lb). FI044A 17. Install the camshaft holders on the respective camshaft with the arrows directed toward the cam gears; then secure with the eight cap screws and tighten to specifications. FI047 www.mymowerparts.com 3-306 FI040B 21. Install the coolant crossover hose on the water pump and cylinder. Tighten the clamps securely. FI161A 22. Install the timing inspection plug on the magneto cover and tighten to specifications. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 23. Place a new O-ring on the drive end of the starter; then place a light coat of grease on the O-ring and install the starter. Secure with the two cap screws and tighten securely. 5. Secure the engine damper stopper to the frame with the cap screws. Tighten only until snug. Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame; then slide the engine rearward as far as possible. FI111 2. Raise the front of the engine and engage the front drive output yoke onto the splined output shaft; then lower the engine into the mounting brackets. 6. Making sure the thermostat bleed valve is correctly oriented, install the thermostat housing and engine damper mount; then secure with the two cap screws and tighten to specifications. Tighten the engine damper stopper cap screws (from step 5) to specifications. FI105B FI108A 3. Install the front through-bolt; then install the rear through-bolt. Secure with new self-locking nuts and tighten to specifications. 4. Align the rear drive flanges and secure with four cap screws. Tighten to specifications. NOTE: It is advisable to apply the brake lever lock when tightening the cap screws securing the rear driveshaft. FI112 7. Using a new O-ring, install the intake pipe on the cylinder head making sure the UP mark is directed toward the top of the engine; then secure with the two cap screws and tighten securely. www.mymowerparts.com CD824 3-307 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI104A FI092A 10. Secure the engine ground wire and main harness ground to the engine at the appropriate position on the left-side cover and tighten the cap screw to specifications. FI103 8. Install the throttle body into the intake pipe and tighten the clamp securely. 9. Connect the ISC valve connector, TPS connector, coolant temperature sensor connector, and fuel injector connector to the appropriate sensor; then connect the gasline hose connector to the fuel rail. FI084 11. Connect the gear position indicator connector (A), stator connector (B), and the crankshaft position sensor connector (C) to the main wiring harness. FI089A FI083A 12. Connect the starter positive cable to the starter and tighten the nut securely. www.mymowerparts.com 3-308 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI094 FI114 13. Place the shifter arm on the shift shaft aligning the match marks; then install the cap screw and tighten to specifications. 3 FI098A FI085A 14. Connect the speed sensor connector to the housing. 19. Secure the air filter to the throttle body and tighten the clamp securely; then connect the air intake temperature sensor to the harness connector. 15. Install the exhaust pipe to the cylinder head using a new grafoil seal; then secure with two nuts and finger-tighten only. Connect the exhaust pipe to the muffler and secure with the two exhaust springs. Tighten the two exhaust pipe nuts securely. 16. Secure all wiring to the frame and upper engine bracket with cable ties. 17. Secure the two coolant hoses to the engine. FI099A 18. Place the air filter housing into position on the frame and mount the intake air pressure sensor on the mount; then install the air diverter assembly and connect and secure the inlet air duct to the air filter housing. FI082A www.mymowerparts.com 3-309 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 20. Secure the crankcase vent hose to the air filter housing; then install the air filter and secure with the air filter housing cover noting the alignment marks. 23. Place the left-side footwell and foot peg in position on the frame; then secure with existing hardware. Tighten securely. CD782 FI081A 24. Install the front body panel with existing hardware (see Section 8). 25. Place the side panels into position. 26. Place the battery into position in the battery compartment; then install the battery cables and vent hose. Secure with the battery cover. ! CAUTION FI035A 21. Connect the V-belt cooling inlet duct and outlet boot and secure with the hose clamps. Tighten securely. 22. Connect the spark plug cap/high tension lead to the spark plug; then connect the primary coil wire and ground wire to the coil. Tighten the ground wire cap screw securely. FI066A www.mymowerparts.com 3-310 Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 27. Add proper amounts of engine/transmission oil and coolant. 28. Install the seat. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 FUEL/LUBRICATION/COOLING 4 TABLE OF CONTENTS www.mymowerparts.com Carburetor Specifications ........................................ 4-2 Carburetor Schematics (400/500/650 H1)............... 4-2 Throttle Body Assembly (700 EFI) .......................... 4-2 Carburetor (400/500/650 H1) .................................. 4-2 Electronic Fuel Injection (700 EFI) .......................... 4-7 Cleaning and Inspecting Carburetor (400/500/650 H1) ................................................. 4-8 Throttle Cable Free-Play ......................................... 4-9 Engine RPM (Idle) ................................................... 4-9 Gas Tank ................................................................. 4-9 Gas/Vent Hoses ...................................................... 4-9 Electric Fuel Pump (700 EFI) ................................. 4-9 Vacuum Pulse Fuel Pump (400/500/650 H1) .......... 4-9 Oil Flow Charts...................................................... 4-10 Oil Filter/Oil Pump ................................................. 4-11 Testing Oil Pump Pressure.................................... 4-11 Oil Cooler (400) ..................................................... 4-12 Oil Cooler (650 H1) ............................................... 4-12 Liquid Cooling System (500/650 H1/700 EFI) ....... 4-13 Radiator................................................................. 4-13 Hoses/Thermostat (500/650 H1/700 EFI) ............. 4-14 Fan ........................................................................ 4-14 Servicing Water Pump (500 - Manual Transmission).............................. 4-14 Servicing Water Pump (500/650 H1/700 EFI - Automatic Transmission)................................. 4-15 Testing Electric Fuel Pump (700 EFI).................... 4-18 Testing Vacuum Pulse Fuel Pump (400/500/650 H1) ............................................... 4-20 4-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor Specifications ITEM Throttle Body Assembly (700 EFI) 400 500 650 H1 Carburetor Keihin CVK34 Keihin CVK36 Keihin CVK36 Main Jet 135 138 132 Slow Jet 38 40 40 Pilot Screw Setting (turns) 1 3/4 1 3/4 1 1/4 Jet Needle NAZG NFKG NFKS Idle RPM (engine warm) 1250-1350 1250-1350 1250-1350 Starter Jet 75 85 85 Float Arm Height 17 mm (0.7 in.) 17 mm (0.7 in.) 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm 3-6 mm 3-6 mm (1/8-1/4 in.) (1/8-1/4 in.) (1/8-1/4 in.) Carburetor Schematics (400/500/650 H1) KEY 1. 2. 3. 4. 5. 6. 7. Throttle Cable ISC Valve O-Ring Cover Sensor Assy Screw Screw 8. 9. 10. 11. 12. 13. 14. Hose Injector Assy O-Ring Seal Delivery Pipe Air Pressure Sensor Holder 0741-277 Carburetor (400/500/650 H1) ! WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. REMOVING KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Cover Screw Spring Vacuum Piston Spring Seat Jet Needle Needle Jet Jet Holder Main Jet Slow Jet Starter Jet Float Valve Clip Float 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Float Pin Pilot Screw Spring Washer O-Ring Idle Adjust Screw Washer Spring Plate Screw Electric Choke Choke Cover Float Chamber Assy 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. O-Ring Screw Spring Diaphragm Assy Pump Housing U-Ring Screw Screw Throttle Cable Cover Screw Vent Hose 0739-656 www.mymowerparts.com 4-2 1. Remove the seat. 2. As necessary to access the carburetor, remove the air-intake snorkel, the air cleaner housing cover, or the air cleaner housing. 3. Disconnect the gasline hose from the carburetor to the fuel pump. 4. Loosen the flange clamps; then remove the carburetor from the intake pipe. 5. Remove the screw securing the throttle actuator cover to the carburetor; then remove the cover. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC743 CH015D 6. Remove the throttle cable from the actuator arm. 2. Remove the vacuum piston assembly from the carburetor body. Account for a spring, spring seat, and the jet needle. 4 CC742 7. Loosen the outer jam nut securing the throttle cable to the carburetor body; then route the cable out of the way. CC746 3. Remove the three screws securing the pump housing. Account for the diaphragm assembly, spring, and U-ring (in the housing). CC741 8. Disconnect the electric choke lead from the wiring harness. 9. Disconnect the vent hose; then remove the carburetor. CC748 4. Remove the Phillips-head screws securing the float chamber; then remove the chamber. Account for the O-ring. DISASSEMBLING 1. Remove the four Phillips-head screws securing the top cover; then remove the cover. www.mymowerparts.com 4-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Note the locations of the jets, pilot screw, and holder for disassembling procedures. CC749 CC761A 7. Secure the needle jet holder with a wrench; then remove the main jet. 8. Remove the needle jet holder; then remove the needle jet, slow jet, and the starter jet. 9. Remove the pilot screw. Account for a spring, washer, and an O-ring. CC750 5. Remove the float pin. CC758 10. Unscrew and remove the idle adjust screw. Account for the spring and washer. CC752 6. Lift the float assembly from the carburetor. Account for the float valve. ASSEMBLING 1. Screw the idle adjust screw into the carburetor making sure the washer and spring are properly positioned. 2. Install the pilot screw, spring, washer, and O-ring. CC753 www.mymowerparts.com 4-4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Check float arm height by placing the carburetor on its side w/float contacting the needle; then measure with a caliper the height when the float arm is in contact with the needle valve. Float arm height should be 17 mm (0.7 in.). 6. Place the float chamber into position making sure the O-ring is properly positioned; then secure with the Phillips-head screws. CC758 NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the recommended number of turns as an initial setting. NOTE: Note the locations of the jets and holder during assembling procedures. CC750 4 CC761A 3. Install the slow jet. Tighten securely. CC749 4. Install the main jet into the needle jet holder and tighten securely; then install the needle jet and needle jet holder assembly into the carburetor and tighten securely. 7. Place the U-ring into the pump housing. Position the spring and diaphragm assembly (lip toward the carburetor) onto the carburetor; then secure the assembly with the pump housing and three screws. Tighten securely. 5. Place the float assembly (with float valve) into position and secure to the carburetor with the float pin. CC748 CC753 www.mymowerparts.com 4-5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION It is important to press down on the pump housing until it contacts the carburetor to make sure the diaphragm lip is properly seated in the groove in the carburetor. If the diaphragm is not properly seated, leakage will occur. 8. Place the jet needle, spring seat, and spring into the vacuum piston; then place the assembly down into the carburetor. CC740A 3. Place the throttle cable into position and secure by tightening the outer jam nut. CC746 9. Place the top cover into position; then secure with the Phillips-head screws. Tighten securely. CC741 4. Connect the throttle cable to the actuator arm. CH015D INSTALLING CC742 1. Connect the gas and vent hoses onto the carburetor. 2. Connect the electric choke lead to the wiring harness. www.mymowerparts.com 4-6 5. Place the throttle actuator cover into position on the carburetor; then secure with the screw. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 1. Turn the ignition switch to the OFF position; then remove the ignition switch key. ! WARNING Do not turn the ignition switch to the ON position with the hoses removed. Gasoline will be pumped by the electric fuel pump causing a safety hazard. 2. Disconnect the battery; then remove the seat. CC743 6. Position the carburetor in the air cleaner boot and intake pipe assembly; then secure with the clamps. 7. Connect the hose from the carburetor to the gas tank. 3. Remove the storage compartment cover and air filter housing cover; then remove the air filter. 4. Loosen the clamp securing the air filter housing boot to the throttle body inlet; then remove the boot from the throttle body. 8. As necessary, secure the air-intake snorkel, the air cleaner housing cover, or the air cleaner housing. 9. Install the seat. 4 Electronic Fuel Injection (700 EFI) ! WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. TROUBLESHOOTING FI081B 5. Slowly disconnect the gasline hose connector from the fuel rail. ! WARNING Gasoline may be under pressure. Place an absorbant towel under the connector to absorb any gasoline spray when disconnecting. 1. Verify that the electric fuel pump is operating by listening for a “whirring” sound for several seconds after the ignition switch is turned to the ON position. If no sound can be heard, see Testing Electric Fuel Pump (700 EFI) in this section. 2. Check for a flashing EFI icon on the LCD display. If EFI is flashing, see ECU Error Codes (700 EFI) in Section 5. 3. Make sure there is sufficient, clean gas in the gas tank. 4. Verify that the battery is sufficiently charged to crank the engine over at normal speed. 5. Check the air filter housing and air filter for contamination. Clean or replace as necessary (see Section 2). www.mymowerparts.com FI092A 6. Remove the screw securing the throttle actuator cover to the throttle body; then remove the cover. 7. Remove the throttle cable from the actuator arm. 4-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Loosen the outer jam nut securing the throttle cable to the throttle body; then route the cable out of the way. 9. Remove the four electrical connectors from the throttle body components. 4. Connect the four electrical connectors to the throttle body components. 5. Install the air filter housing boot and secure with the clamp; then install the air filter, air filter cover, storage compartment, and storage compartment cover. 6. Install the seat making sure it locks securely in place. Cleaning and Inspecting Carburetor (400/500/650 H1) FI089A 10. Remove the cap screws securing the intake pipe to the cylinder head and remove the throttle body assembly; then remove the intake pipe from the throttle body. Account for an O-ring. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. ! WARNING When drying components with compressed air, always wear safety glasses. ! CAUTION DO NOT place any non-metallic components in parts-cleaning solvent because damage or deterioration will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner. 2. Soak for 30 minutes; then rinse with fresh parts-cleaning solvent. FI104A 11. Use tape to cover and seal the intake opening. ! CAUTION Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine is turned over or started. INSTALLING 1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely. 2. Place a new O-ring in the intake pipe; then position the pipe onto the engine and secure with two cap screws. 3. Connect the throttle cable to the throttle body and adjust throttle free-play (see Section 2); then connect the gasline hose. www.mymowerparts.com 4-8 3. Wash all non-metallic components with soap and water. Rinse thoroughly. 4. Dry all components with compressed air only making sure all holes, orifices, and channels are unobstructed. 5. Inspect the carburetor body for cracks, nicks, stripped threads, and any other imperfections in the casting. 6. Inspect the vacuum piston/diaphragm for cracks, imperfections in the casting, or cracks and tears in the rubber. 7. Inspect float for damage. 8. Inspect gasket and O-rings for distortion, tears, or noticeable damage. 9. Inspect tips of the jet needle, pilot screw, and the needle jet for wear, damage, or distortion. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Inspect the slow jet and main jet for obstructions or damage. 1. Clean all gas tank components with parts-cleaning solvent. NOTE: If the slow jet is obstructed, the mixture will be extremely lean at idle and part-throttle operation. 2. Inspect all hoses for cracks or leaks. 11. Inspect the float valve for wear or damage. 12. Inspect the carburetor mounting flange for damage and tightness. Throttle Cable Free-Play To adjust throttle cable free-play, see Section 2. Engine RPM (Idle) (Carbureted Models) To adjust the idle RPM, see Section 2. Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. 3. Inspect tank cap and tank for leaks, holes, and damaged threads. INSTALLING 1. Place the gas tank into position in the frame; then install the cap screws. Tighten securely. 2. Connect the gas hose from the carburetor/throttle body; then connect the fuel gauge connector. 3. Install the vent hose; then fill the gas tank with gasoline. 4. Start the engine and inspect for leakage. 5. Install the rear fenders and rack (see Section 8); then install the seat making sure it latches securely. 4 Gas/Vent Hoses Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the carburetor/throttle body vent hose. Make certain that the vent hose is securely connected to the carburetor/throttle body and the opposite end is always open. Electric Fuel Pump (700 EFI) REMOVING 2. Remove the rear rack and fenders (see Section 8). The electric fuel pump and fuel level sensor are not serviceable components. If either fails, the fuel pump assembly must be replaced. 3. Disconnect the hose from the fuel pump to the carburetor/throttle body. NOTE: To test the fuel pump, see Testing Electric Fuel Pump (700 EFI) in this section. 1. Remove the seat. 4. Remove the cap screws securing the gas tank to the frame. 5. Disconnect the fuel gauge connector; then remove the gas tank. Vacuum Pulse Fuel Pump (400/500/650 H1) CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. The vacuum pulse fuel pump is not a serviceable component. If the pump fails, it must be replaced. www.mymowerparts.com 4-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Oil Flow Charts 400/500 (Manual Transmission) Intake and Exhaust Cam Faces Cam Drive Chain Intake Rocker Arm Shaft Driveshaft Left End Bearing Secondary Idle Gears Driveshaft Countershaft Left End Bearing Camshaft Starter Gear Countershaft Cylinder Head Conrod Big-End Bearing Cylinder Wall Piston Wall Piston Ring Cylinder Crankshaft One-Way Clutch Countershaft Gears Secondary Input Gears Driveshaft Gears and Reverse Gears Primary Driven Gear Spacer Oil Gallery Second Clutch Drive and Driven Plates Oil Filter Crankshaft Right End Bearing First Clutch Shoe Relief Valve Oil Pump Bevel Gears Oil Strainer Oil Sump ATV-0111 400/500/650 H1 (Automatic Transmission) Intake and Exhaust Cam Faces 700 EFI Cam Drive Chain Intake, Rocker Arm Shaft Starter Clutch Camshaft Cylinder Head Cover Conrod Big-End Bearing Cylinder Wall Piston Wall Piston Ring Cylinder Head Crankshaft Cylinder Oil Gallery Crankshaft Right End Bearing First Clutch Shoe Oil Filter Bevel Gears Driveshaft Gears & Reverse Gears Relief Valve Oil Pump Oil Strainer OIL SUMP ATV-1102 FI449 www.mymowerparts.com 4-10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Oil Filter/Oil Pump NOTE: Whenever internal engine components wear excessively or break and whenever oil is contaminated, the oil pump should be replaced. The oil pump is not a serviceable component. Testing Oil Pump Pressure FI439A NOTE: The engine must be warmed up to the specified temperature for this test. 1. Connect the Tachometer (p/n 0644-275) to the engine. 2. Connect the Oil Pressure Test Kit (p/n 0644-495) to the oil filter drain plug (400/500), in the oil pressure test port (700 EFI), or to the upper oil cooler hose at the engine (650 H1). NOTE: Some oil seepage may occur when installing the oil pressure gauge. Wipe up oil residue with a cloth. 3. Start the engine and run at 3000 RPM. The oil pressure gauge must read as specified. 400 (Manual Transmission) OIL PRESSURE 4 0.6-1.0 kg/cm² (9-14 psi) Oil Temperature - 60°C (140°F) 400 (Automatic Transmission) OIL PRESSURE 1.1-1.5 kg/cm² (16-21 psi) Oil Temperature - 60°C (140°F) 500 (Manual Transmission) OIL PRESSURE 1.2-1.6 kg/cm² (17-23 psi) Oil Temperature - 60°C (140°F) 500 (Automatic Transmission) CD457B OIL PRESSURE 1.3-1.7 kg/cm² (18-24 psi) Oil Temperature - 60°C (140°F) 650 H1 OIL PRESSURE (From Oil Cooler) 1.40-2.46 kg/cm² (15-25 psi) Oil Temperature - 60°C (140°F) 700 EFI OIL PRESSURE 1.4-1.8 kg/cm² (20-26 psi) Oil Temperature - 110°C (230°F) PR265B NOTE: If the oil pressure is lower than specified, check for an oil leak, damaged oil seal, defective oil pump, or oil cooler. www.mymowerparts.com 4-11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the oil pressure is higher than specified, check for too heavy engine oil weight (see Section 2), clogged oil passage, clogged oil filter, or improper installation of the oil filter. INSTALLING 1. Place the cooler into position in the frame. 2. Secure the cooler to the frame with the cap screws and grommets. Oil Cooler (400) KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Oil Cooler Assy Oil Cooler Screen Thumb Screw Shroud Machine Screw Fan Drain Plug O-Ring Grommet Nut w/Washer Shoulder Screw Bushing Clamp Hose Fitting O-Ring Cap Screw Fitting AL651D 3. Install the hoses onto their respective fittings and secure with the clamps. Oil Cooler (650 H1) 0739-573 REMOVING NOTE: It is not necessary to drain the engine oil for this procedure. 1. Remove the input and output hoses from the fittings on the cooler. ! CAUTION Elevate and secure the hoses to avoid oil spillage. 2. Remove the cap screws securing the oil cooler to the frame. Account for grommets. REMOVING 1. Disconnect the oil hoses from the oil cooler located on the back of the radiator. 2. Remove the radiator (see Radiator) in this section. 3. Remove the fan and fan shroud; then separate the oil cooler from the radiator. INSTALLING 1. Place the oil cooler into position on the radiator and secure with the retainer brackets; then install the fan shroud and fan. 2. Install the radiator (see Radiator) in this section. 3. Connect the oil hoses to the oil cooler and tighten the clamps securely. 4. Warm up the engine and check for leaks; then shut off the engine and check for the proper oil level on the oil level stick. Add sufficient amount of oil to raise the level above the lower level mark. AL651D 3. Remove the oil cooler from the frame. www.mymowerparts.com 4-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Liquid Cooling System (500/650 H1/700 EFI) The cooling system should be inspected daily for leakage and damage. Also, the coolant level should be checked periodically. To check the cooling system, see Section 2. CC863 Radiator CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Flush the radiator with water to remove any contaminants. 2. Inspect the radiator for leaks and damage. 3. Inspect all hoses for cracks and deterioration. 4. Inspect all fasteners and grommets for damage or wear. 0732-411 REMOVING 1. Drain the coolant at the engine. 2. Remove the front rack (see Section 8). 3. Remove the front bumper and front fender panel (see Section 8). 4. Remove the upper and lower coolant hoses. INSTALLING 1. Position the fan/fan shroud assembly on the radiator; then secure with existing hardware. 2. Place the radiator with grommets and collars into position on the frame; then install the cap screws and nuts. Tighten securely. 3. Install the upper and lower coolant hoses; then secure with hose clamps. 5. Remove the cap screws and nuts securing the radiator to the frame. 6. Disconnect the fan wiring from the main wiring harness; then remove the radiator/fan assembly and account for the grommets and collars. 7. Remove the fan/fan shroud assembly from the radiator. AF734D 4. Install the front bumper and front fender panel (see Section 8). 5. Install the front rack (see Section 8). www.mymowerparts.com 4-13 4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. 3. Slide the upper hose onto the thermostat housing and radiator. Secure with the two hose clamps. 7. Connect the fan wiring to the main wiring harness. 4. Install the lower coolant hose onto the water pump housing and radiator. Secure with the two hose clamps. Hoses/Thermostat 5. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. (500/650 H1/700 EFI) Fan REMOVING 1. Drain approximately one qt of coolant from the cooling system. 2. Remove the two cap screws securing the thermostat housing to the cylinder head. Account for an O-ring and a thermostat. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the thermostat for corrosion, wear, or spring damage. 2. Using the following procedure, inspect the thermostat for proper operation. A. Suspend the thermostat in a container filled with water. B. Heat the water and monitor the temperature with a thermometer. C. The thermostat should start to open at 73.5-76.5° C (164-170° F) on the 500/650 H1 and 80.5-83.5° C (177-182° F) on the 700 EFI. D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear. NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. INSTALLING 1. Place the thermostat and O-ring into the thermostat housing; then secure the thermostat housing to the cylinder head with the two cap screws. 2. Install the crossover coolant hose onto the water pump and engine water inlet. Secure with the two hose clamps. www.mymowerparts.com 4-14 REMOVING 1. Remove the radiator (see Radiator in this section). 2. Remove the fan assembly from the radiator. INSTALLING 1. Position the fan assembly on the radiator; then secure with existing hardware. NOTE: The fan wiring must be in the upper-right position. 2. Install the radiator (see Radiator in this section). Servicing Water Pump (500 - Manual Transmission) REMOVING/DISASSEMBLING KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Case Cap Screw Gasket O-Ring Impeller Mechanical Seal Seal Cap Screw Washer Washer Cap Screw Cap Screw Shaft w/Bearing Joint Pin 0738-290 1. Drain the coolant. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the three cap screws securing the water pump case. Note the position of the long cap screw and account for the O-ring. 3. Remove the impeller cap screw, washer, and gasket. 4. Remove the mechanical seal using this procedure. A. Tap the tip of a small sheet metal screw into the inner-metal edge of the seal. Servicing Water Pump (500/650 H1/700 EFI Automatic Transmission) NOTE: When servicing the water pump, it will be necessary to install a new oil seal and a new mechanical seal. B. Grip the screw with a pair of vise-grip pliers and pull the seal out. Account for the pump drive seal. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all pump components in solvent. 2. Inspect the mechanical seal and pump drive seal for damage. NOTE: If the mechanical seal and/or pump drive seal are damaged, they must be replaced as a set. 3. Inspect the impeller for corrosion or damage. ASSEMBLING/INSTALLING NOTE: Treat seals and O-rings with clean antifreeze for initial lubrication. 1. Press the mechanical seal with pump drive seal into the impeller by hand. 2. Install the mechanical seal assembly onto the water pump shaft and secure with the cap screw, washer, and gasket. Tighten the cap screw securely. 4 KEY 1. Water Pump Assy 2. Cap Screw (Drain) 3. Gasket 4. O-Ring 5. Impeller/Shaft 6. Mechanical Seal 7. 8. 9. 10. 11. 12. 13. 14. Oil Seal Bearing E-Ring O-Ring Screw Cap Screw Driven Gear Shaft 15. 16. 17. 18. 19. 20. 21. Pin Circlip Shaft Circlip Drive Gear Pin Circlip 0737-766 REMOVING 1. Remove the radiator cap; then remove the water pump drain and drain the coolant. 3. Place the water pump case into position and secure with the three cap screws. Note the position of the long cap screw from removal. 4. Fill the cooling system with the recommended amount of antifreeze. NOTE: While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system. 5. Check the entire cooling system for leakage. www.mymowerparts.com CC789 2. Drain the oil from the engine/transmission. 3. Remove the four torx-head cap screws securing the front and rear fenders to the footrest; then remove the four cap screws securing the footrest to the frame. Remove the footrest. 4-15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. From inside the left-front wheel-well, remove the two torx-head cap screws securing the fender to the frame. CC786A DISASSEMBLING CC788A 5. Compress the tabs on the coolant hose clamps and slide the clamps away from the hose ends approximately 51 mm (2 in.); then remove both hoses from the water pump. 1. Finish removing the two Phillips-head cap screws securing the cover to the bearing housing; then remove the cover. Account for the O-ring. 2. Remove the E-ring securing the impeller/shaft to the bearing housing; then remove the impeller/shaft. 3. Using Seal Removal Tool (p/n 0644-072), remove the mechanical seal and the oil seal from the bearing housing. CC784 6. Using an impact driver, loosen but do not remove the two Phillips-head cover screws. CC772 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all oil-pump components in cleaning solvent. CC785A 7. Remove the two cap screws securing the water pump to the engine; then remove the water pump. www.mymowerparts.com 4-16 2. Inspect the impeller/shaft for corrosion or damage. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ASSEMBLING 1. Place the new oil seal into the bearing housing; then using a seal driver, gently tap the seal down until it is fully seated. CC786A CC778 2. Place the new mechanical seal into the bearing housing; then tap it down until it is fully seated. NOTE: A large deep-well socket can be used to drive the seal down evenly. 3. Install the impeller/shaft assembly into the bearing housing; then secure with the E-ring. NOTE: Make sure the E-ring is fully seated and the impeller rotates freely. 4. While holding the bearing housing assembly in position on the engine, slowly rotate the impeller until the impeller/shaft engages properly with its slot in the driven shaft. CC785A 2. Connect the two coolant hoses to the water pump and secure with the clamps. 3. From inside the left-front wheel-well, secure the fender to the frame with the two torx-head cap screws. Tighten securely. NOTE: The bearing housing will be flush with the engine when the two shafts are properly engaged. ! CAUTION Failure to properly engage the two shafts could cause serious engine damage. 5. With the bearing housing assembly in position on the engine, place the cover (with O-ring installed) into position on the housing; then loosely secure with the two Phillips-head cap screws. INSTALLING 1. Secure the water pump to the engine with the two cap screws tightened securely; then tighten the two Phillips-head cap screws securely. CC788A 4. Place the footrest into position on the frame and loosely secure with four cap screws; then secure the front and rear fenders to the footrest with the four torx-head cap screws. Tighten the four torx-head cap screws securely; then tighten the remaining cap screws to specifications. 5. Fill the engine/transmission with the proper amount of recommended oil. 6. Fill the cooling system with the proper amount of recommended coolant. www.mymowerparts.com 4-17 4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system. 7. Check the entire cooling system for leakage. ! CAUTION After operating the ATV for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary. FI092A Testing Electric Fuel Pump 3. Turn the ignition switch to the ON position. The fuel pressure should build until the pump shuts off. Pressure should read 3.0 kg-cm2 (43 psi). (700 EFI) 4. If the pump is not running, disconnect the fuel pump/tank sensor connector by reaching under the rear rack from behind. ! WARNING 5. Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire; then turn the ignition switch to the ON position. The meter should read battery voltage. If battery voltage is indicated and the fuel pump does not run, replace the pump assembly. If no battery voltage is indicated, check the ECU and the vehicle tilt sensor. Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. AT THIS POINT Prior to removing the electric fuel pump, the following check should be performed to determine that removal is necessary. 1. Turn the ignition switch ON and listen for a momentary “whirring” sound of the pump building pressure. If the sound is heard (10 seconds), no electrical checks are necessary. Turn the ignition switch OFF. 2. Disconnect the gasline hose from the throttle body; then install a suitable pressure gauge. ! WARNING Gasoline may be under pressure. Place an absorbant towel under the connector to absorb any gasoline spray when disconnecting. REMOVING 1. Remove the rear rack and fenders (see Section 8); then disconnect the power supply/ fuel gauge connector. 2. Remove the spring clamp; then remove the fuel hose. 3. Remove the screws securing the fuel pump to the gas tank; then make a reference mark on the fuel pump and tank. 4. Lift out the fuel pump assembly carefully tilting it forward to clear the voltage regulator; then guide the pump and float lever through the opening in the gas tank. ! CAUTION Take care not to damage the float or float arm or replacement of the entire assembly will be necessary. 5. Using duct tape or other suitable means, cover the fuel pump opening. www.mymowerparts.com 4-18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING AT THIS POINT If the pump has failed earlier test and must be replaced, proceed to INSTALLING. 1. Inspect the fuel screen and blow clean with low pressure compressed air. 2. Move the float lever and check for free movement. The float assembly should return to the lower position without force. If not, replace the fuel pump assembly. 3. Test the fuel gauge tank sensor by connecting a multimeter (A) to the fuel sensor leads (B); then select OHMS. The multimeter should show 5 ohms at full fuel position (C) and 95 ohms at empty fuel position (D). B. Engage the tabs (C) of the fuel gauge tank sensor into the mounting slot (B) and press toward the bottom of the fuel pump to latch in place; then connect the two-wire connector (A). INSTALLING 1. Mark the new fuel pump with a reference mark in the same location as the removed pump; then place the new gasket on the pump. 2. Remove the material covering the fuel pump opening; then carefully guide the fuel pump into position taking care not to damage the float or float lever. 4 KX190 3. Rotate the fuel pump until the match marks align; then install the mounting screws and tighten securely using a crisscross pattern. ATV2116 NOTE: If readings are erratic, clean the resistor wiper and resistor with clean alcohol and retest. If still not correct, replace the fuel gauge tank sensor. 4. To replace the fuel gauge tank sensor, use the following procedure. A. Disconnect the two-wire connector (A); then press the fuel gauge tank sensor toward the top of the fuel pump to release it from the mounting slot (B). NOTE: It is important to install the fuel pump with the correct orientation to ensure adequate float lever clearance. 4. Connect the wires, fuel hose, and spring clamp; then turn the ignition switch to the ON position. Note that the fuel pump runs momentarily and the fuel gauge indicates the proper fuel level. 5. With the transmission in neutral and brake lever lock engaged, start the engine and check for normal operation. Check for any fuel leaks. 6. Install any wire ties that were removed; then install the rear fenders, rack, and seat making sure the seat locks securely. FI460A www.mymowerparts.com 4-19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Testing Vacuum Pulse Fuel Pump (400/500/650 H1) 2. Start the engine. Fuel pump pressure should read 0.18-0.25 kg/cm2 (2.5-3.5 psi). REMOVING 1. Remove the seat; then remove the three clamps securing the gas hoses and vacuum hose and disconnect the hoses. ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. AT THIS POINT Prior to removing the vacuum pulse fuel pump, the following check should be performed to determine that removal is necessary. 1. Disconnect the fuel pump/carburetor hose at the fuel pump; then connect a hose and suitable pressure gauge to the fuel pump output fitting. CD766A 2. Remove the two machine screws and flange nuts securing the fuel pump to the electrical tray; then remove the pump. INSTALLING 1. Place the fuel pump into position on the electrical tray; then secure with the machine screws and flange nuts. Tighten securely. 2. Connect two gas hoses and one vacuum hose; then secure with the clamps. CD815 CD816 www.mymowerparts.com 4-20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 ELECTRICAL SYSTEM TABLE OF CONTENTS www.mymowerparts.com Specifications .......................................................... 5-2 Battery..................................................................... 5-2 RPM Limiter............................................................. 5-2 Testing Electrical Components ................................ 5-2 Accessory Receptacle/Connector ........................... 5-3 Brakelight Switch (Auxiliary).................................... 5-3 Brakelight Switch (Handlebar Control) .................... 5-3 Oil Temperature and Cooling Fan Switches (400)... 5-4 Coolant Temperature and Cooling Fan Switches (500/650 H1) ........................................................ 5-5 Cooling Fan Switch and Engine Coolant Temperature (ECT) Sensor (700 EFI) .................. 5-5 Fan Motor ................................................................ 5-6 Fuse Block/Power Distribution Module .................... 5-6 Fuses ...................................................................... 5-7 Ignition Coil ............................................................. 5-7 EFI Sensors/Components (700 EFI) ....................... 5-8 Electronic Speedometer Speed Sensor .................. 5-8 Ignition Switch ....................................................... 5-10 Handlebar Control Switches.................................. 5-10 Front Drive Selector Switch ................................... 5-11 Front Drive Selector Actuator ................................ 5-12 Differential Lock Switch ........................................ 5-12 Magneto Coils (400/500/650 H1) .......................... 5-13 Stator Coil/Crankshaft Position (CKP) Sensor (700 EFI) ............................................................ 5-14 Starter Motor ......................................................... 5-15 Starter Relay ......................................................... 5-20 CDI Unit (400/TBX/500/650 H1)............................ 5-20 Electronic Control Unit (ECU) (700 EFI)................ 5-20 Regulator/Rectifier................................................. 5-21 Neutral Start/Front Drive Actuator/Start-in-Gear/ Differential Lock/2WD Relays............................. 5-21 Headlights ............................................................. 5-21 Taillight - Brakelight ............................................... 5-21 Ignition Timing ....................................................... 5-22 ECU Error Codes (700 EFI) .................................. 5-22 Tilt Sensor (700 EFI) ............................................. 5-23 Throttle Position Sensor (TPS) (700 EFI).............. 5-24 5-1 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications 400 700 EFI Ignition Timing N/A Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) 8000-12,000 ohms Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Cap Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Ignition Coil Resistance Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance Ignition Coil Peak Voltage Less than 1 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) (primary) (primary/ CDI) 250-375 DC volts (terminal to ground) Ignition Coil Peak Voltage 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) (charging) Less than 1 ohm (black to black) (trigger) (source) Magneto Coil Peak Voltage (trigger) (source) 5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black) 500/650 H1 Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms (500) 4000 ohms (650 H1) Ignition Coil Resistance Ignition Coil Peak Voltage Less than 1 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) (primary) (primary/ CDI) 140.0-215.0 DC volts - 500 142.4-213.6 DC volts - 650 H1 (terminal to ground) MAGNETO Magneto Coil Resistance Magneto Coil Peak Voltage 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) (charging) Less than 1 ohm (black to black) (trigger) (source) (trigger) (source) Stator Coil Output (no load) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) 60 AC volts @ 5000 RPM (black to black) www.mymowerparts.com 5-2 (ECU) 80 volts or more (wire (+) to ground) MAGNETO Stator Coil Resistance MAGNETO Magneto Coil Resistance (primary) Less than 1 ohm (terminal (+) to terminal (-)) (secondary) 12k-19k ohms (high tension - plug cap to terminal (+)) (crankshaft 150-250 ohms (blue to white) position sensor) (charging) Less than 1 ohm (yellow to yellow) Crankshaft Position Sensor Peak Voltage Stator Coil Output 5.0 volts or more (blue to white) (no load) 75 AC volts @ 5000 RPM (yellow to yellow) Battery For battery related information, see Section 2. RPM Limiter NOTE: The ATV is equipped with a CDI unit that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire. Testing Electrical Components All of the electrical tests should be made using the Fluke Model 73 Multimeter (p/n 0644-191) and when testing peak voltage, the Peak Voltage Reading Adapter (p/n 0644-307) must be used. If any other type of meter is used, readings may vary due to internal circuitry. When troubleshooting a specific component, always verify first that the fuse(s) are good, that the bulb(s) are good, that the connections are clean and tight, that the battery is fully charged, and that all appropriate switches are activated. NOTE: For absolute accuracy, all tests should be made at room temperature of 68° F. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Accessory Receptacle/Connector NOTE: This test procedure is for either the receptacle or the connector. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, switch, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance. RESISTANCE (Switch Connector) VOLTAGE 1. Turn the ignition switch to the ON position; then set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the red/white wire or the positive connector; then connect the black tester lead to ground. 3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, receptacle, connector, or the main wiring harness. ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire. Brakelight Switch (Auxiliary) 5 The switch connector is the two-prong connector on the brake switch lead above the transmission. NOTE: The ignition switch must be in the ON position. AR626D 3. When the brake pedal is depressed, the meter must show less than 1 ohm. VOLTAGE (Wiring Harness Side) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester to the orange wire; then connect the black tester lead to ground. NOTE: If the meter shows more than 1 ohm of resistance, replace the switch. Brakelight Switch (Handlebar Control) To access the connector, remove the access panel. NOTE: The ignition switch must be in the ON position. VOLTAGE (Wiring Harness Connector) 1. Set the meter selector to the DC Voltage position. AR627D 3. The meter must show battery voltage. www.mymowerparts.com 2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground. 5-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Oil Temperature and Cooling Fan Switches (400) NOTE: This model has an oil temperature switch and a cooling fan switch. 1. Connect the meter leads (selector in the OHMS position) to the switch contacts. AR622D 3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, switch, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance. 2. Suspend the switch and a thermometer in a container of oil; then heat the oil. NOTE: Neither the switch nor the thermometer should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire holders to suspend switch and thermometer. RESISTANCE (Switch Connector) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. NOTE: The brake lever must be compressed for this test. Also, the ignition switch must be in the OFF position. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire. 733-554C 3. On the oil temperature switch when the oil temperature reaches 160° C (320° F), the meter should read a closed circuit. 4. On the oil temperature switch, allow the oil to cool, and when the temperature is at (or just before) a temperature of 140° C (284° F), the meter should read an open circuit. 5. On the cooling fan switch when the temperature reaches 120° C (248° F), the meter should read a closed circuit. 6. On the cooling fan switch, allow the oil to cool, and when the temperature is at (or just before) a temperature of 110° C (230° F), the meter should read an open circuit. 7. If the readings are not as indicated, the switch must be replaced. AR621D 3. When the lever is compressed, the meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, replace the switch. www.mymowerparts.com 5-4 8. Apply thread tape to the threads of the switch; then install the switch and tighten securely. 9. Connect the switch leads. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Coolant Temperature and Cooling Fan Switches (500/650 H1) Cooling Fan Switch and Engine Coolant Temperature (ECT) Sensor (700 EFI) 1. Connect the meter leads (selector in the OHMS position) to the switch contacts. 2. Suspend the switch and a thermometer in a container of water; then heat the water. NOTE: Neither the switch nor the thermometer should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire holders to suspend switch and thermometer. 1. Connect the meter leads (selector in OHMS position) to the switch/sensor terminals. 2. Suspend the switch/sensor and a thermometer in a container of water; then heat the water. NOTE: Neither the switch/sensor nor the thermometer should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire holders to suspend the switch/sensor and thermometer. 3. On the cooling fan switch when the water temperature reaches approximately 93° C (199° F), the meter should read less than 1.0 ohm. 4. On the cooling fan switch, allow the water to cool and when the temperature reaches approximately 87° C (189° F), the meter should read an open circuit. 733-554E 3. On the coolant temperature switch when the water temperature reaches 112-118° C (234-244° F), the meter should read a closed circuit. 4. On the coolant temperature switch, allow the water to cool, and when the temperature is within a temperature range of 108-111° C (226-232° F), the meter should read an open circuit. 5. On the cooling fan switch when the temperature reaches 66-68° C (150-155° F), the meter should read a closed circuit. 6. On the cooling fan switch, allow the water to cool, and when the temperature is within a temperature range of 62-65° C (145-149° F), the meter should read an open circuit. 5. On the ECT sensor when the temperature reaches 20° C (68° F), the meter should read approximately 2.45k ohms. 6. On the ECT sensor when the temperautre reaches 50° C (122° F), the meter should read approximately 800 ohms. 7. On the ECT sensor when the temperautre reaches 80° C (176° F), the meter should read approximately 318 ohms. 8. On the ECT sensor when the temperautre reaches 110° C (230° F), the meter should read approximately 142 ohms. 9. If the readings are not as indicated, the switch/sensor must be replaced. 10. Install the switch/sensor and tighten securely. 11. Connect the leads. 7. If the readings are not as indicated, the switch must be replaced. 8. Install the switch and tighten securely. 9. Connect the switch leads. www.mymowerparts.com 5-5 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot or replace the switch/component, the connector, or the switch wiring harness. Fan Motor The connector is the black two-prong one located behind the fan assembly. NOTE: The ignition switch must be in the ON position. VOLTAGE (Main Harness Connector to Fan Motor) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the black/red wire (500/650 H1/700 EFI) or the black/orange wire (400); then connect the black tester lead to ground. 3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, motor, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good. The connector should be checked for resistance. NOTE: To determine if the fan motor is good, connect the blue wire from the fan connector to a 12 volt DC power supply; then connect the black wire from the fan connector to ground. The fan should operate. ! CAUTION Care should be taken to keep clear of the fan blades. Fuse Block/Power Distribution Module The fuses are located in a power distribution module under the seat. If there is any type of electrical system failure, always check the fuses first. NOTE: The ignition switch must be in the LIGHTS position. 1. Remove all fuses from the distribution module. 2. Set the meter selector to the DC Voltage position. RESISTANCE (Fan Motor Connector) 3. Connect the black tester lead to ground. ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the black wire. 4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. 5. The meter must show battery voltage from one side of the connector terminal ends. NOTE: Battery voltage will be indicated from only one side of the fuse holder connector terminal; the other side will show no voltage. NOTE: When testing the HI fuse holder, the headlight dimmer switch must be in the HI position; when testing the LIGHTS fuse holder, the headlight dimmer switch can be in either position. NOTE: If the meter shows no battery voltage, troubleshoot the battery, switches, distribution module, or the main wiring harness. AR645D 3. The meter must show less than 1 ohm. www.mymowerparts.com 5-6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuses ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one spade end of the fuse; then connect the black tester lead to the other spade end. CF202A 3. The meter must show less than 1 ohm resistance. If the meter reads open, replace the fuse. NOTE: Make sure the fuses are returned to their proper position according to amperage. Refer to the fuse block cover for fuse placement. Ignition Coil CD882B The ignition coil is on the frame above the engine. To access the coil, the side panel (see Section 2) must be removed. 5 RESISTANCE ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. NOTE: For these tests, the meter selector should be set to the OHMS position and the primary wire(s) should be disconnected. CF234A Primary Winding 1. Connect the red tester lead to either terminal; then connect the black tester lead to the other terminal or on 500 models, to a suitable ground. FI066B 2. The meter reading must be within specification. Secondary Winding www.mymowerparts.com 1. Remove the plug cap from the high tension lead; then connect the red tester lead to the high tension lead. 5-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. On the 400/650 H1, connect the black tester lead to either primary connector; on the 500/700 EFI, connect the black tester lead to the coil frame or to the primary connector. 3. The meter reading must be within specification. NOTE: If the meter does not show as specified, replace ignition coil. PEAK VOLTAGE (500/650 H1/700 EFI) NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter (p/n 0644-191) with Peak Voltage Reading Adapter (p/n 0644-307). If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests. Spark Plug Cap 1. Connect the red tester lead to one end of the cap; then connect the black tester lead to the other end of the cap. Primary/CDI (500/650 H1)/ ECU (700 EFI) NOTE: The CDI/ECU is located beneath the seat near the battery. 1. Set the meter selector to the DC Voltage position; then disconnect the blue/white primary wire from the coil. 2. Connect the red tester lead to the primary wire; then connect the black tester lead to ground. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. AR603D 2. The meter reading must be within specification. NOTE: If the meter does not read as specified, replace the spark plug cap. EFI Sensors/ Components (700 EFI) PEAK VOLTAGE (400) NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter (p/n 0644-191) with Peak Voltage Reading Adapter (p/n 0644-307). If any other type of tester is used, readings may vary due to internal circuitry. CRANKSHAFT POSITION (CKP) SENSOR NOTE: The battery must be at full charge for these tests. AIR PRESSURE SENSOR (APS) Primary/CDI NOTE: The CDI is located beneath the seat and fender panel near the battery. 1. Set the meter selector to the DC Voltage position; then disconnect the blue/white primary wire from the coil. 2. Connect the red tester lead to the primary wire; then connect the black tester lead to ground. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. www.mymowerparts.com 5-8 To test the CKP sensor, see Stator Coil/Crankshaft Position (CKP) Sensor (700 EFI) in this section. 1. Disconnect the APS connector from the pressure sensor located on the right front-side of the air filter housing. 2. Select DC Voltage on the tester and turn the ignition switch to the ON position. 3. Connect the black tester lead to the black/green wire and the red tester lead to the brown wire. The meter should read 4.5-5.5 DC volts. If the meter does not read as specified, check the ECU connector or wiring. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Connect the APS to the harness; then using MaxiClips (p/n 0744-041), connect the red tester lead to the brown/white wire and the black tester lead to the black/green wire. With the engine running at idle speed, the meter should read approximately 2.6 DC volts. NOTE: If the meter does not read as specified, check the hose connecting the APS to the intake pipe or replace the sensor. Electronic Speedometer Speed Sensor NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the sensor harness (400/500 manual models) or on the speed sensor (500 auto/650 H1/700 EFI models) for contamination, broken pins, and/or corrosion. 4. The meter must show 6 DC volts (500 auto/650 H1/700 EFI) or 12 DC volts (400/500 manual). 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead (S) pin. 6. Slowly move the ATV forward or backward; the meter must show 0 and 6 DC volts alternately (500 auto/650 H1/700 EFI) or 0 and 12 DC volts alternately (400/500 manual). NOTE: If the sensor tests are within specifications, the speedometer must be replaced. See Section 9. To replace a speed sensor, use the following procedure. 1. Disconnect the three-wire connector from the speed sensor harness or from the speed sensor; then remove the Allen-head cap screw securing the sensor to the sensor housing. 2. Remove the sensor from the sensor housing accounting for an O-ring. 5 CD884A CD070 3. Install the new speed sensor into the housing with new O-ring lightly coated with multi-purpose grease; then secure the sensor with the Allen-head cap screw (threads coated with blue Loctite #242). Tighten securely. CD885B 1. Set the meter selector to the DC Voltage position. 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V); then connect the black tester lead to the ground lead (G). CD071 3. Turn the ignition switch to the ON position. www.mymowerparts.com 5-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. The meter must show less than 1 ohm. Ignition Switch On the 400/500, the connector is the black three-wire one beneath the steering post cover. On the 650 H1/700 EFI, the connector is a four-wire one. To access the connector, the cover must be removed. VOLTAGE NOTE: Perform this test on the lower side of the connector. 1. Set the meter selector to the DC Voltage position. 2. Connect the red meter lead to the red wire; then connect the black meter lead to ground. 10. With the switch in the OFF position, connect the red tester lead to the red wire and the black tester lead to each of the remaining wires. The meter must show an open circuit on all wires. 11. On the 650 H1/700 EFI, connect the red tester lead to the red wire and the black tester lead to the brown wire. With the switch in the ON position, the meter must show 980-1020 ohms. NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot or replace the switch/component, the connector, or the switch wiring harness. Handlebar Control Switches 3. Meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery or the main wiring harness. RESISTANCE ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. NOTE: Perform this test on the upper side of the connector. The connector is the yellow one next to the steering post. To access the connector, the steering post cover and the right-side fender splash shield must be removed (see Section 8). NOTE: These tests should be made on the top side of the connector. ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. RESISTANCE (HI Beam) 1. Turn the ignition switch to the ON position. 1. Set the meter selector to the OHMS position. 2. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the yellow wire; then connect the black tester lead to the gray wire. 3. Connect the red tester lead to the red wire; then connect the black tester lead to the orange wire (400/500) or to the red/black wire (650 H1/700 EFI). 4. The meter must show less than 1 ohm. 5. Turn the ignition switch to the LIGHTS position. 6. Connect the red tester lead to the red wire; then connect the black tester lead to the orange wire (400/500) or to the red/black wire (650 H1/700 EFI). 7. The meter must show less than 1 ohm. 8. Connect the red tester lead to the red wire; then connect the black tester lead to the gray wire. www.mymowerparts.com 5-10 3. With the dimmer switch in the HI position, the meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot or replace the switch/component, the connector, or the switch wiring harness. RESISTANCE (LO Beam) 1. Connect the red tester lead to the white wire; then connect the black tester lead to the gray wire. 2. With the dimmer switch in the LO position, the meter must show an open circuit. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter reads resistance, troubleshoot or replace the switch/component, the connector, or the switch wiring harness. DIODE (Starter Button) NOTE: If voltage is not as specified, check the condition of the battery in the meter prior to replacing the switch. A low battery will result in a low voltage reading during a diode test. 1. Set the meter selector to the Diode position. 2. Connect the red tester lead to the orange/white wire; then connect the black tester lead to the yellow/green wire. 3. With the starter button depressed, the meter must show 0.5-0.7 DC volts. 4. With the starter button released, the meter must show 0 DC volts. 5. Connect the red tester lead to the yellow/green wire; then connect the black tester lead to the orange/white wire. 2. Connect the red tester lead to one red/yellow wire; then connect the black tester wire to the other red/yellow wire. The meter must show less than 1 ohm. 3. Depress and hold the reverse override button. The meter must show an open circuit. 4. Connect the red tester lead to the blue wire; then connect the black meter lead to the black wire. The meter must show an open circuit. 5. Depress and hold the reverse override button. The meter must show less than 1 ohm. NOTE: If the meter does not show as specified, replace the switch/component, connector, or switch harness. Front Drive Selector Switch 6. With the starter button depressed, the meter must show 0 DC volts. The connector is the two-wire black snap-lock one in front of the steering post. To access the connector, the cover must be removed. NOTE: If the meter does not show as specified, replace the switch/component, connector, or switch harness. NOTE: Resistance tests should be made with the connector disconnected and on the selector-side of the connector. RESISTANCE (Emergency Stop) RESISTANCE 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the orange wire; then connect the black tester lead to the orange/white wire. 3. With the switch in the OFF position, the meter must show an open circuit. 4. With the switch in the RUN position, the meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot or replace the switch/component, the connector, or the switch wiring harness. RESISTANCE (Reverse Override) The connector is the four-prong white one next to the steering post. To access the connector, the front rack and front fenders must be removed (see Section 8). 1. Set the meter selector to the OHMS position. www.mymowerparts.com ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the red wire; then connect the black tester lead to the white wire. 3. With the selector switch in the 2WD position, the meter must show a closed circuit. 4. With the selector switch in the 4WD position, the meter must show an open circuit. NOTE: If the meter does not show as specified, replace the front drive selector switch. VOLTAGE NOTE: The battery must be connected when performing voltage tests. 1. Set the meter selector to the DC Voltage position. 5-11 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the black tester lead to the negative battery terminal. 3. Connect the red tester lead to the red wire on the harness side of the connector. 4. Turn the ignition switch to the RUN position. 5. The meter must show 12 DC volts. NOTE: If the meter shows other than specified, check the harness, connector, 30 amp fuse, and battery connections. NOTE: If the voltage readings are as specified and the actuator does not function correctly, replace the actuator (see Section 6). Differential Lock Switch NOTE: The following procedure does not include the 400 TRV model. VOLTAGE Front Drive Selector Actuator 1. Select DC Voltage on the multimeter; then connect the red tester lead to the switch terminal (leaving the wire connected) and the black tester lead to ground. NOTE: With the engine stopped and the ignition switch in the ON position, a momentary “whirring” sound must be noticeable each time the selector switch is moved to 2WD and 4WD. Test the switch, 30 amp fuse, and wiring connections prior to testing the actuator. NOTE: The differential must be in the unlocked position for this procedure. VOLTAGE 1. Select the 2WD position on the front drive selector switch; then disconnect the connector on the actuator wiring harness. 2. With the ignition switch in the OFF position, connect the black tester lead to the black wire in the supply harness; then connect the red tester lead to the orange wire in the supply harness. 3. Turn the ignition switch to the ON position. The meter must show 12 DC volts. 4. Connect the red tester lead to the white/red wire in the supply harness. The meter must show 12 DC volts. 5. Select the 4WD position on the front drive selector switch; then connect the red tester lead to the white/red wire in the supply harness. The meter must show 0 DC volts. NOTE: The 4WD icon on the LCD should illuminate. 6. Connect the red tester lead to the orange wire in the supply harness. The meter must show 12 DC volts. www.mymowerparts.com 5-12 CD575 2. Turn the ignition switch to the ON position. The meter must show 12 DC volts. NOTE: If no voltage is indicated, check the wiring harness, fuse, or battery connections. 3. Select the lock position on the differential. The meter should drop to 0 volts, and the front drive selector actuator switch should operate to engage 4-wheel drive. NOTE: It may be necessary to rock the ATV slightly to engage the differential lock fully. NOTE: The 4WD and the LOCK icons on the LCD should illuminate. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Stator Coil - No Load) The connector is the black three-pin one on the right side of the engine just above the starter motor. NOTE: Test the connector that comes from the engine. 1. Set the meter selector to the AC Voltage position. CD576 2. Test between the three black wires for a total of three tests. 3. With the engine running at the specified RPM, all wire tests must show 60 AC volts. ! CAUTION Do not run the engine at high RPM for more than 10 seconds. NOTE: If both stator coil tests failed, check all connections, etc., and test again. If no voltage is present, replace the stator assembly. CF094C 4. If the differential lock engages (front wheels locked) and the voltage does not drop to 0, the switch is faulty and must be cleaned or replaced. RESISTANCE (Charging Coil) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. Magneto Coils (400/500/650 H1) VOLTAGE (Stator Coil - Regulated Output) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the negative battery post. 3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14-15.5 DC volts. ! CAUTION Do not run the engine at high RPM for more than 10 seconds. NOTE: If voltage is lower than specified, test stator coil - no load. 1. Set the meter selector to OHMS position. 2. Test between the three black wires for a total of three tests. 3. The meter reading must be within specification. RESISTANCE (Trigger Coil) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Disconnect the gray four-pin connector on the right side of the engine just above the starter motor. 2. Set the meter selector to the OHMS position. 3. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire. The meter reading must be within specification. www.mymowerparts.com 5-13 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Source Coil) Magneto Coil (Trigger) 1. Set the meter selector to the OHMS position. 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the yellow wire; then connect the black tester lead to the white wire. 2. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire. 3. The meter reading must be within specification. 3. Crank the engine over using the electric starter. NOTE: If the meter shows other than specified in any resistance test, replace the stator assembly. 4. The meter reading must be within specification. PEAK VOLTAGE (400) NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter (p/n 0644-191) with Peak Voltage Reading Adapter (p/n 0644-307). If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests. Magneto Coil (Source) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the yellow wire; then connect the black tester lead to the white wire. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. Magneto Coil (Trigger) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire. Stator Coil/Crankshaft Position (CKP) Sensor (700 EFI) 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. Magneto Coil (Source) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the yellow wire; then connect the black tester lead to the white wire. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. PEAK VOLTAGE (500/650 H1) NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter (p/n 0644-191) with Peak Voltage Reading Adapter (p/n 0644-307). If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests. www.mymowerparts.com 5-14 VOLTAGE (Regulator/Rectifier - Output) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the negative battery post. 3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14-15.5 DC volts. ! CAUTION Do not run the engine at high RPM for more than 10 seconds. NOTE: If voltage is lower than specified, test stator coil - no load. VOLTAGE (Stator Coil - No Load) The connector is the black three-pin one on the left side above the shift lever. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Test the connector that comes from the engine. 1. Set the meter selector to the AC Voltage position. 2. Test between the three yellow wires for a total of three tests. 3. The meter reading must be within specification. RESISTANCE (Crankshaft Position Sensor) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the white wire. The meter reading must be within specification. PEAK VOLTAGE FI083B 3. With the engine running at a constant 5000 RPM, all wire tests must be within specifications. NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter (p/n 0644-191) with Peak Voltage Reading Adapter (p/n 0644-307). If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests. Crankshaft Position Sensor ! CAUTION Do not run the engine at high RPM for more than 10 seconds. 1. Set the meter selector to the DC Voltage position. NOTE: If both stator coil tests failed, check all connections, etc., and test again. If no voltage is present, replace the stator assembly. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the white wire. 3. Crank the engine over using the electric starter. RESISTANCE (Charging Coil) 4. The meter reading must be within specification. ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. Starter Motor 1. Set the meter selector to OHMS position. 2. Test between the three yellow wires for a total of three tests. REMOVING/DISASSEMBLING 1. Disconnect the battery. ! CAUTION Always disconnect the negative battery cable from the battery first; then disconnect the positive cable. 2. Remove the nut securing the positive cable to the starter; then remove the cable from the starter. 3. Remove the two cap screws securing the starter to the crankcase; then remove the starter. Account for the wiring forms and an O-ring. FI083B www.mymowerparts.com 5-15 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. For assembly purposes, scribe a line across the outside of the starter assembly. BC007 AR652D 5. Remove the two long starter cap screws securing the starter components. 6. Remove the front cover from the starter housing and armature shaft. Account for a seal protector and three washers. BC010 10. Remove the nut from the positive post. Account for the lock washer, flat washer, a fiber washer, and an O-ring. BC003 7. Remove the rear cover. 8. Slide the armature free of the starter housing. BC008 11. Remove the positive brush assembly from the starter housing. BC006 9. Bend the two positive brushes outward; then remove the brush holder. www.mymowerparts.com 5-16 BC009 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Thoroughly clean all components except the armature and brushes in parts-cleaning solvent; then dry with compressed air. ! CAUTION Do not wash the armature and brushes in any kind of solvent. Use only compressed air and a clean dry, lint-free cloth. 2. Inspect all threaded areas for damage or stripped threads. 3. Inspect the brush holder assembly and brushes for damage or wear. Using a caliper, measure the length of the brushes. If brush measurement is less than 10.1 mm (0.40 in.), replace with new brushes and brush springs as a set. 4. Inspect the brush leads for cracks, wear, or fraying. If any of these conditions exist, replace with new brushes and brush springs as a set. 5. Inspect the rear cover bushing for wear. 6. Inspect the front cover bearing for wear. 7. Inspect the brass commutator end of the armature for any discolored spots or damage. If the commutator is lightly discolored or damaged, the armature must be replaced. This is a molded commutator and turning it down in a lathe should not be attempted. ! CAUTION Do not use emery cloth to clean the commutator as emery particles will become imbedded in the brass commutator resulting in a short circuit. Use only #200 grit sandpaper. ATV-1054 ! CAUTION Buildup in the grooves must be removed to prevent any chance of an electrical arc between individual sections of the commutator. 10. Inspect the commutator for shorting using a multimeter and the following procedure. A. Set the selector to the OHMS position. B. Touch the black lead to the armature shaft. C. Using the red tester lead, probe the commutator end of the armature. The meter indicator should not change. If the indicator shows resistance, the armature is shorted and must be replaced. 11. Inspect the armature for shorting using a “growler” and the following procedure. A. Place the armature in the “growler.” B. While holding a metal strip on the armature, rotate the armature an entire revolution. If the metal strip vibrates at any point on the armature, the armature is shorted and must be replaced. 8. Inspect the commutator end of the armature for buildup in the grooves. Carefully remove any buildup by undercutting using a thinly ground hacksaw blade. Do not undercut any deeper than the original groove which can be seen by looking at the end of the commutator. 9. Using a caliper, measure the undercut. Maximum undercut groove must be 0.2 mm (0.008 in.). 0725-653 12. Inspect the ground brushes to make sure they are properly grounded. Use a multimeter and the following procedure. www.mymowerparts.com A. Set the selector to the OHMS position. 5-17 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Touch the black tester lead to a ground brush. C. Touch the red tester lead to the brush holder assembly. NOTE: If no resistance is indicated, check the ground connection for tightness and for cleanliness. If there is still no meter indication, replace the brush assembly. ASSEMBLING/INSTALLING 1. Install the positive post on the positive brush assembly; then install on the starter housing. BC010 4. Install the armature into the starter housing; then while holding the brushes out, slide the commutator into the brush holder. BC009 2. On the positive post, install an O-ring washer, a fiber washer, a flat washer, and a lock washer. Secure with the nut. BC006 5. Apply a small amount of grease to the rear cover bushing; then install the cover on the starter housing making sure the reference marks align. BC008 3. Align the tab on the brush holder with the notch in the starter housing; then install. BC013 6. In order, install the thick metal washer, thin metal washer, and the fiber washer on the armature shaft; then install the housing O-ring on the starter housing. www.mymowerparts.com 5-18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 BC014 AR653D 7. Apply a small amount of grease to the front cover bearing and seal; then install the seal protector. 10. Apply a small amount of grease to the O-ring seal on the starter; then install the starter into the crankcase. Secure with two cap screws and wiring forms. 11. Secure the positive cable to the starter with the nut. 12. Connect the battery. TESTING VOLTAGE Perform this test on the starter motor positive terminal. To access the terminal, slide the boot away. BC015 NOTE: The ignition switch must be in the ON position, the emergency stop switch in the RUN position, the reverse lever (on manual transmission models) in the FORWARD position, and the shift lever (on automatic transmission models) in the NEUTRAL position. 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the starter terminal; then connect the black tester lead to ground. BC004 3. With the starter button depressed, the meter must show battery voltage and the starter motor should operate. 8. Place the front cover onto the starter housing making sure it seats properly. 9. Apply red Loctite #271 to the threads of the two long cap screws and install. Tighten to 0.8-1.2 kg-m (6-9 ft-lb). AR607D www.mymowerparts.com 5-19 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter showed battery voltage but the starter did not operate or operated slowly, inspect battery voltage (at the battery), starter motor condition, and/or ground connections. NOTE: If the meter showed no battery voltage, inspect the main fuse, ground connections, starter motor lead, battery voltage (at the battery), starter relay, or the neutral start relay. Starter Relay KX059A 1. Remove the seat; then using the multimeter set to the DC Voltage position, check the relay as follows. 2. Connect the red tester lead to the positive battery terminal; then connect the black tester lead to the starter cable connection on the starter relay. The meter must show battery voltage. 5. Depress the starter button and observe the multimeter. NOTE: If battery voltage is indicated, replace the starter relay. If no voltage is indicated, proceed to Neutral Start Relay check. CDI Unit (400/TBX/500/650 H1) The CDI is located beneath the seat near the battery. NOTE: The CDI unit is not a serviceable component. If the unit is defective, it must be replaced. The CDI is rarely the cause for electrical problems; however, if the CDI is suspected, substitute another CDI unit to verify the suspected one is defective. KX206A NOTE: Make sure that the ignition switch is in the ON position, transmission in neutral, brake lock released, and the emergency stop switch in the RUN position. 3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts and a “click” should be heard from the relay. NOTE: If a “click” is heard and any voltage is indicated by the multimeter, replace the starter relay. If no “click” is heard and the multimeter continues to indicate battery voltage, proceed to step 4. 4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the black wire. www.mymowerparts.com 5-20 NOTE: Prior to replacing the CDI unit to assure the CDI unit is defective, it is advisable to perform a CDI peak voltage test (see Ignition Coils in this section) and/or perform a continuity test of the wiring harness from the CDI connector to the CDI unit. Electronic Control Unit (ECU) (700 EFI) The electronic control unit (ECU) is located beneath the seat near the battery. NOTE: The ECU is not a serviceable component. If the unit is defective, it must be replaced. The ECU is rarely the cause for electrical problems; however, if the ECU is suspected, substitute another ECU to verify the suspected one is defective. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Error codes can be cleared by following the procedures located in the ECU Error Codes (700 EFI) sub-section in this section. Regulator/Rectifier BULB VERIFICATION (Low and High Beam) NOTE: Perform this test on each headlight bulb. Also, a 12-volt external power supply w/jumpers will be needed. 1. Disconnect the wiring harness from the bulb to be tested. The regulator/rectifier is located under the rear rack and rear fenders. TESTING 1. Start engine and warm up to normal operating temperatures; then connect a multimeter to the battery as follows. 2. Select the DC Voltage position; then connect the red tester lead to the positive battery post and the black tester lead to the negative battery post. 3. Start the engine and slowly increase RPM. The voltage should increase with the engine RPM to a maximum of 15.5 DC volts. NOTE: If voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or corroded. Clean and tighten battery connections or replace the regulator/rectifier. If voltage does not rise, check Voltage (Charging Coil - No Load) in this section. If charging coil voltage is normal, replace the regulator/rectifier. Neutral Start/Front Drive Actuator/Start-in-Gear/ Differential Lock/2WD Relays The relays are identical plug-in type located on the power distribution module. Relay function can be checked by switching relay positions. The relays are interchangeable. NOTE: The module and wiring harness are not a serviceable component and must be replaced as an assembly. Headlights The connectors are the four 2-prong ones secured to the front bumper supports (two on each side) with cable ties. 2. Connect the power supply (positive) to one bulb contact; then connect the power supply (negative) to the remaining bulb contact. 3. The bulb should illuminate. 4. If the bulb fails to illuminate, it must be replaced. VOLTAGE NOTE: Perform this test in turn on the main harness side of all four connectors. Also, the ignition switch must be in the LIGHTS position. NOTE: The LO beam is the outside bulb, and the HI beam is the inside bulb. 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to one wire; then connect the black tester lead to the other wire. 3. With the dimmer switch in the LO position, test the two outside connectors (LO beam). The meter must show battery voltage. 4. With the dimmer switch in the HI position, test the two inside connectors (HI beam). The meter must show battery voltage. NOTE: If battery voltage is not shown in any test, inspect the fuses, battery, main wiring harness, connectors, or the left handlebar switch. Taillight - Brakelight The connector is the 3-prong one located under the rear fender assembly. BULB VERIFICATION NOTE: Perform this test on the taillight-brakelight side of the connector. Also, a 12-volt external power supply (jumper) will be needed. www.mymowerparts.com 5-21 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Connect the power supply (positive) to the middle terminal; then connect the power supply (negative) to the bottom terminal. Ignition Timing 2. The taillight should illuminate. 3. With the negative power supply still connected, connect the positive supply wire to the top terminal. The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components. To verify engine timing, see Section 2. 4. The brakelight should illuminate. NOTE: If either the taillight or brakelight fails to illuminate, inspect the bulb, the connectors, or the component wiring harness. ECU Error Codes (700 EFI) VOLTAGE (Taillight) NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the LIGHTS position. 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the white wire; then connect the black tester lead to the black wire. 3. With the ignition key in the LIGHTS position, the meter must show battery voltage. NOTE: If the meter shows no voltage, inspect fuses, wiring harness, connectors, and switches. VOLTAGE (Brakelight) NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the ON position and the brake (either foot pedal or hand lever) must be applied. If a sensor fails or an out-of-tolerance signal is sensed by the ECU, an error code will be generated by the ECU. This will result in the analog needle swinging full scale (LE model) or the LCD gauge going blank (standard model). The EFI icon will flash. To read the error code, use the following procedure. 1. Make sure the ignition switch is in the OFF position; then remove the seat. ! CAUTION Always make sure the ignition switch is in the OFF position before disconnecting the ECU. 2. Locate the diagnostic plug in front of the ECU; then remove the black rubber cap. 3. Connect the Diagnostic Harness (p/n 0486-219) to the diagnostic plug. NOTE: Make sure the brake lever (hand) and brake pedal (auxiliary) are properly adjusted for this procedure. 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the red/blue wire; then connect the black tester lead to the black wire. 3. With either brake applied, the meter must show battery voltage. NOTE: If the meter shows no voltage, inspect bulb, fuses, wiring harness, connectors, and switches. www.mymowerparts.com 5-22 ATV-112 4. Turn the ignition switch to the ON position and read the error code on the LCD. Refer to the following ECU Error Code List to identify the specific problem area. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ECU Error Code List • • • • • • • • • • • • • EC00 EC12 EC13 EC14 EC15 EC20 EC21 EC23 EC24 EC32 EC40 EC41 EC99 = = = = = = = = = = = = = No Fault Detected CKP (Crankshaft Position) Sensor APS (Air Pressure Sensor) TPS (Throttle Position Sensor) Water Temperature Sensor Differential Lock Relay Air Temperature Sensor Tilt Sensor Ignition Coil #1 Fuel Injector #1 ISC Valve Fuel Pump Relay Start Not Possible NOTE: EC99 indicates that the engine will not start and that the spark plug and fuel pump are disabled. EC99 will be displayed following EC23 (Tilt Sensor), EC24 (Ignition Coil), etc. To clear an error code after repairs or adjustments are made, install the Diagnostic Harness (p/n 0486-219) by connecting it to the diagnostic plug; then turn the ignition switch to the ON position. After three seconds, turn the ignition switch to the OFF position and disconnect the diagnostic harness. When the ignition switch is turned on, the error code should not be displayed. CD706A 2. Turn the ignition switch to the ON position. The multimeter should read battery voltage. If battery voltage is not indicated, check the 30-amp fuse, wiring harness, or the ignition switch. 3. Remove the red tester lead and connect to the blue/brown wire (B). The multimeter should read 0 DC volts. If the specified voltage is not indicated, check wire connections at the CDI or substitute another CDI to verify the test. 5 Tilt Sensor (700 EFI) ! WARNING Incorrect installation of the tilt sensor could cause sudden loss of engine power which could result in loss of vehicle control resulting in injury or death. ! CAUTION Do not drop the tilt sensor as shock can damage the internal mechanism. SUPPLY VOLTAGE CD706B OUTPUT VOLTAGE NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected. 1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the rear frame. 1. Disconnect the three-wire connector from the sensor; then select DC Voltage on the multimeter and connect the red tester lead to the orange wire (C) and the black tester lead to the black wire (A). www.mymowerparts.com 5-23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD707 2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. 3. Connect the red tester lead to the blue/brown wire (B) and the black tester lead to the black/yellow wire (A); then turn the ignition switch ON and observe the meter. The meter should read 0.8-3.0 DC volts. CD705A Throttle Position Sensor (TPS) (700 EFI) INSPECTING 1. Remove the left-side engine cover; then disconnect the three-wire TPS connector plug. CD705B 4. Tilt the sensor 60° or more to the left and right observing the meter. The meter should read 4.0-8.0 DC volts after approximately one second in the tilted position. If the meter readings are not as specified, the tilt sensor is defective. FI450A NOTE: Prior to testing the TPS, inspect the three-wire plug connector on the main harness and the three-pin plug on the TPS for contamination, broken pins, and/or corrosion. 2. Make sure the ignition switch is in the OFF position; then select the DC Voltage position on the meter. 3. Connect the black tester lead to spade terminal C and the red tester lead to spade terminal A. Turn the ignition switch to the ON position. The meter should read 4.5-5.5 DC volts. CD709 NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up. www.mymowerparts.com 5-24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI456A 4. Remove the red tester lead from spade terminal A and connect it to spade terminal B. The meter should read 4.5-5.5 DC volts. FI455A NOTE: If any meter reading is not as specified, replace or adjust the TPS (see INSTALLING/ADJUSTING in this sub-section). NOTE: If the meter does not read as specified, check for poor connections at the ECU or open/broken wires in the wiring harness. 7. Connect the positive lead to the battery; then connect the negative lead. ! CAUTION 8. Connect the main harness TPS connector to the TPS; then using MaxiClips (p/n 0744-041), connect the black tester lead to the green/black wire. Always make sure the ignition switch is in the OFF position before disconnecting the ECU. 5. Turn the ignition switch to the OFF position; then disconnect the battery (negative cable first). 5 ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 6. Select the OHMS position on the meter; then perform the following resistance tests on the TPS. A. Pin (B) to ground - infinity (open circuit). B. Pin (A) to pin (B) - approximately 1.22k ohms (throttle closed). C. Pin (A) to pin (B) - approximately 4.36k ohms (throttle full-open). D. Pin (A) to pin (C) - approximately 4.05k ohms. FI451A 9. Select the DC Voltage position on the meter and turn the ignition switch to the ON position. The meter should read approximately 1.12 DC volts with the throttle closed and approximately 4.32 DC volts with the throttle in the full-open position. NOTE: If the meter readings are as specified, check the main harness connector at the ECU main harness wiring. If the meter readings are not as specified, replace the TPS and adjust to specifications (see INSTALLING/ADJUSTING in this sub-section. ! CAUTION Always make sure the ignition switch is in the OFF position before disconnecting the ECU. 10. Clear all ECU error codes after servicing is complete (see ECU Error Codes (700 EFI) in this section). www.mymowerparts.com 5-25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 1. Remove the left-side engine cover; then disconnect the three-wire TPS connector plug. 4. Turn the ignition switch to the ON position and note the position of the TPS indicator icon (A, B, or C); then adjust the TPS until the TPS icon appears in the center position (B). FI450A FI459A 2. Remove the two screws securing the TPS to the throttle body and remove the TPS. INSTALLING/ADJUSTING 1. Place the TPS into position on the throttle body and secure with the two screws. Do not tighten at this time. 2. Connect the main harness to the TPS. 3. Locate the diagnostic connector under the seat; then install the test plug from Test Plug/Error Code List Kit (p/n 0444-216) onto the connector. FI454A FI459B FI452A 5. Tighten the mounting screws securely; then verify the TPS icon appears in the center position. 6. Remove the test plug; then install the left-side engine cover. www.mymowerparts.com 5-26 FI453A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM 6 TABLE OF CONTENTS www.mymowerparts.com Drive System ........................................................... 6-2 General Information................................................. 6-2 Front Drive Actuator ................................................ 6-3 Front Differential ...................................................... 6-4 Drive Axles ............................................................ 6-18 Rear Gear Case .................................................... 6-22 Hub........................................................................ 6-24 Hydraulic Brake Caliper......................................... 6-24 6-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SPECIAL TOOLS Drive System NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 10. General Information A number of special tools must be available to the technician when servicing the gear case. Description p/n CV Boot Clamp Tool 0444-120 Pinion Gear/Shaft Removal Tool 0444-127 Slide Hammer Kit 0444-225 Internal Hex Socket (48 mm) 0444-104 NOTE: Special tools are available from the Arctic Cat Service Parts Department. TROUBLESHOOTING All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code. A. A “6” or “3.6” on the lower-right corner indicates a 3.6:1 gear set ratio (10:36 teeth). B. A “1” or “3.1” on the lower-right corner indicates a 3.1:1 gear set ratio (11:34 teeth). C. A “4.0” on the lower-right corner indicates a 4.0:1 gear set ratio (9:36 teeth). The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values. Size New Housing Reassembled Housing M6 (Torx T-30 Recess) 1.1-1.3 kg-m (8-9.5 ft-lb) 0.9-1.2 kg-m (6.5-9 ft-lb) M8 (Torx T-40 Recess) 3.5-4.3 kg-m (25-31 ft-lb) 2.9-3.5 kg-m (21-25 ft-lb) M10 (Torx T-50 Recess) 5.1-6.3 kg-m (37-45.5 ft-lb) 4.3-5.3 kg-m (31-38 ft-lb) SPECIFICATIONS Specific specifications regarding the gear cases (capacities, lubricant type, etc.) can be found in Section 1 of this manual. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) www.mymowerparts.com 6-2 If a noise is heard from the gear case area, it can be difficult to locate and/or diagnose. If the noise is related to wheel speed, but not to engine RPM, the problem is probably in the final drive or engine/transmission bevel gear set. When a problem is localized, a number of inspections must be made to pinpoint that problem. The most obvious of the inspections include CV boots, wheel and hub nut tightness, wheel bearing damage, gear case lubricant contamination, low lubricant level, seal leakage, CV joints, or selector arm. NOTE: Small metallic particles will collect on the magnetic drain plug as a normal part of break-in and will also give a metallic cast to drained lubricant. Contamination would include large particles or water which gives a “milky” look to the lubricant. NOTE: Lubricant on a new pinion housing assembly could be grease. If the front of the gear case is leaking at the rear drive boot, wipe excess lubricant from the bottom of the pinion housing; then operate the ATV for a period of time. Inspect the pinion housing area for any signs of leakage. If lubricant is again on the bottom of the pinion housing, the seal must be replaced. Additional troubleshooting could include the following. • Binding/abrupt motion: CV boot torn (grease loss, foreign object damage, broken cage); gear lubricant loss or not filled (bearing seizure, broken gear teeth, seal leakage, bladder or hose leakage, missing filler/drain plug). • Noise from drive system: wheel or gear case bearing damage, improper gear backlash, improper assembly, low or no gear case lubricant. • Lockup: gear case lubricant loss or not filled, water contamination causing bearing seizure. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Drive Actuator 4. Loosen but do not remove the mounting cap screw at the front of the actuator; then slide the actuator to the rear enough to clear the slotted mounting tab and the selector shaft. NOTE: The actuator is not a serviceable component. If it is defective, it must be replaced. NOTE: The actuator will operate only when the ignition switch is in the ON position. The front drive actuator is located on the left side of the front drive input housing. With the engine stopped and the ignition switch in the ON position, a momentary “whirring” sound can be heard each time the front drive selector switch is shifted. If no sound is heard, see Section 5. If the actuator runs constantly or makes squealing or grinding sounds, the actuator must be replaced. AG928 INSTALLING REMOVING 1. Remove the left-front inner fender panel; then disconnect the connector on the actuator harness. 2. Using a T-30 torx wrench, remove the mounting cap screw from the driveshaft side of the actuator. 1. Lubricate the O-ring on the actuator; then ensure that all mounting surfaces are clean and free of debris. 2. Align the actuator with the selector shaft and slide it forward onto the shaft taking care to engage the cap screw in the slot of the front mounting tab. 6 AG926 3. Remove the mounting cap screw from below the actuator on the suspension side. AG925 3. While holding the actuator firmly forward, tighten the front cap screw to hold the actuator in place; then install but do not tighten the two remaining cap screws. AG927 www.mymowerparts.com 6-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Differential NOTE: To remove the rear gear case, see Rear Gear Case in this section. REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. AG928 4. Loosen the front cap screw; then tighten the cap screw on the driveshaft side. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the drain plug and drain the gear lubricant into a drain pan; then reinstall the plug. AG926 NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator. ATV0082A 5. Tighten the remaining cap screws; then connect the electrical plug to the main harness. 6. Turn the ignition switch to the ON position and check the operation by shifting the selector switch several times. 7. Secure the wiring harness to the frame with a nylon cable tie; then install the inner fender panel. 3. Remove the front wheels. 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut and washer. KX041 6. Release the brake lever lock. NOTE: It is not necessary to remove the brake hoses from the calipers for this procedure. www.mymowerparts.com 6-4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the two brake calipers. Account for the four cap screws and four 0.76 mm (0.030 in.) spacer washers. AF628D 11. Pull the steering knuckle away from the axle taking care not to damage the seals with the axle end. AF894D 8. Remove the tie rod cotter pins and discard the pins. KX151 12. Support the axle to not allow it to drop or hang. AF895D 9. Remove the tie rod lock nuts. 6 ! CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. 13. Remove the lower shock bolts. Account for the lock nuts; then move the shocks aside and secure them with a strap. AF896D 10. Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft; then using a rubber mallet, tap the end of the axle and free it from the knuckle assembly. AF897D 14. Remove the upper A-arm lock nuts and cap screws; then remove the A-arms. www.mymowerparts.com 6-5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF610D 15. Using a slide hammer, remove the front axles. CD026 19. Remove the upper differential mounting cap screws. AF899D 16. Remove the inner fender panels. CD016 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case; then remove the actuator. 20. Free the differential assembly from the frame mountings; then shift the differential assembly forward enough to disengage the front driveshaft from the output yoke. AG925 KX161 18. Remove the lower differential mounting cap screw. Account for a lock nut and washers. 21. Place the differential on its right side; then remove it from the frame. www.mymowerparts.com 6-6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX159 Disassembling Input Shaft NOTE: This procedure can be performed on a rear gear case; however, some components may vary from model to model. The technician should use discretion and sound judgment. CD106 3. Using a side-cutter (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing. CD114 4. Remove the input shaft from the pinion housing. 6 CD102 2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for assembling purposes. CD107 5. Using a seal removal tool, remove the input shaft seal. Account for a spacer. CD103 www.mymowerparts.com 6-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside. AF982 6. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and remove the bearing. AF993 AF983 AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Performance Grease (p/n 0436-905). NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air; then lubricate with recommended grease. AF984 KX221 KX219 www.mymowerparts.com 6-8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX222 4. On the 400/500/650 H1, install the input shaft into the housing; then install the front boot and secure with Boot Clamp (p/n 0423-393) and the rear boot with Boot Clamp (p/n 0423-411). CD103 Disassembling Pinion Gear NOTE: This procedure can be performed on a rear gear case. 1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing. Account for the coupler, fork, and spring. CD112 6 KX209 2. Using a T-40 torx wrench, remove the cap screws securing the gear case cover. Account for and make note of the ID tag location for assembling purposes. CD099 5. Place the pinion housing with new gasket onto the gear case housing; then secure with the existing cap screws. Tighten to specifications. NOTE: If a new gear case housing is being installed, tighten the cap screws to 3.5-4.3 kg-m (25-31 ft-lb). KX173 3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring. www.mymowerparts.com 6-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX174 KX177 NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. 4. Remove the splined coupler, shifter fork, pin, and spring of the differential lock assembly and set aside. Note position of parts for assembling purposes. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly. Account for shim(s) and mark as right-side. KX175 5. Make match marks on the left bearing housing and differential housing; then remove the plate and account for a shim. Mark the shim as left-side. KX179 KX176 KX181 www.mymowerparts.com 6-10 7. Using the 48 mm Internal Hex Socket (p/n 0444-104), remove the lock collar securing the pinion gear assembly. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: On a front differential, the lock collar has right-hand threads. On a rear gear case, the lock collar has left-hand threads. CC879 CC875 NOTE: If gears are being replaced, use the existing shims. The numbers are scribed onto the gears: the ring gear has the number on the opposite side of the gears, and the pinion gear has the number on the end of the pinion gear shaft by the splines. If no number is present, it should be considered as being in the 0 category. NOTE: If the gear case housing is being replaced, proceed to the following Shimming Procedure/Shim Selection sub-section. Shimming Procedure/Shim Selection CC876 8. Using the Pinion Gear/Shaft Removal Tool (p/n 0444-127) and a hammer, remove the pinion gear from the gear case housing. 1. Press bearings into bores by outer ring to hard contact with seat. 2. Install the lock collar and tighten to specifications; then on final assembling, stake the lock collar edge approximately 1.5 mm (0.060 in.) into the lower oil channel. CC878 9. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press. Account for a collar and a bearing. CC891 3. Note the following shim selections (shims are nominally 1.5 mm/0.060 in. thick): www.mymowerparts.com 6-11 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 738-268B CC883 A. Cover Side - add value A on the gear case housing to value B (all models except 400 TRV) or value C (400 TRV) on the gear case cover; then add 1.5 mm (0.060 in.). This will give you the proper shim thickness. 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. NOTE: When shimming a rear gear case, add value A to value B on all models. B. Gear Case Side - install a 1.3-1.4 mm (0.050-0.055 in.) shim and tighten the bolts to 3.5-4.3 kg-m (25-31 ft-lb). Verify backlash to be within a range of 0.28-0.38 mm (0.011-0.015 in.) and end-play to be within a range of 0.10-0.20 mm (0.004-0.008 in.). If not within specification range, reselect shim until backlash specification range can be verified. 4. Prior to final assembling, apply molybdenum disulfide grease to all oil seal lips. 5. Prior to final assembling, prelubricate journal on pinion assembly with SAE 80W-90 hypoid gear lubricant prior to pressing assembly into gear case housing. CC884 3. Install the pinion gear assembly into the housing. Using the 48 mm Internal Hex Socket (p/n 0444-104), secure the pinion gear assembly with the existing lock collar. Tighten to specifications. NOTE: On a front differential, the lock collar has right-hand threads. On a rear gear case, the lock collar has left-hand threads. Assembling Pinion Gear 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar. CC890 4. Place a punch on the edge of the lock collar in the oil gallery area; then using a hammer, stake the lock collar to ensure that the collar will remain securely tightened. CC882 www.mymowerparts.com 6-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC891 CD103 5. Install the shift fork shaft w/spring into the gear housing making sure the shaft O-ring is positioned to the inside. CD110 CC892 6. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket. 8. Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear. Install the ring gear in the housing; then install the outside shim with the chamfer side of the shim toward the ring gear. NOTE: The spider and ring gear assembly must be replaced as a complete unit. CC893 7. Place the input shaft assembly onto the gear housing; then secure with the existing cap screws. Tighten to specifications. CC896 NOTE: If a new gear housing is being installed, tighten the cap screws to 3.5-4.3 kg-m (25-31 ft-lb). www.mymowerparts.com 6-13 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX174 CC897 11. Making sure the O-ring is properly positioned on the gear case housing, install the housing with existing hardware. Account for the ID tag. Tighten the cap screws to specifications. NOTE: Grease can be applied to the O-ring for ease of assembling. NOTE: If a new gear case housing is being installed, tighten the cap screws to 3.5-4.3 kg-m (25-31 ft-lb). KX178 9. Install the left bearing housing aligning the match mark to the mark on the differential housing. Removing Needle Bearing NOTE: Removing the needle bearing is rarely necessary. Avoid removing the needle bearing unless the bearing is clearly damaged. NOTE: This procedure can be performed on a rear gear case. 1. Place a 6.35 mm (1/4 in.) drill bit on the inside surface of the needle bearing (against the bottom side); then drill through the pinion shaft needle bearing housing. KX177 10. Install the differential lock assembly into the bearing housing; then place the O-ring on the gear case housing. CC885 2. Using a propane torch, heat the area surrounding the needle bearing to soften the Loctite. www.mymowerparts.com 6-14 KX175 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC886 CC889 3. Using a flat-nosed punch, drive the bearing out of the housing. 3. Install the pinion shaft and secure with the existing 48 mm lock collar. Tighten to specifications. CC887 CC890 Installing Needle Bearing 1. Apply red Loctite #271 to the outside of a new bearing; then place the new bearing into the housing. 4. Place a punch on the edge of the lock collar in the oil gallery area; then using a hammer, stake the lock collar to ensure that the collar will remain securely tightened. CC891 5. Install the pinion housing. CC888 2. Using a suitable driver, install the needle bearing into the gear case housing making sure the bearing is seated. NOTE: Do not push the bearing too far into the housing. Removing/Installing Axle Seal NOTE: This procedure can be performed on a rear gear case. 1. Remove the seal using a seal removal tool. www.mymowerparts.com 6-15 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC899 2. Using a press, remove the bearing. CD018 5. Repeat steps 1-4 for the opposite side. INSTALLING DIFFERENTIAL 1. Align the splined input yoke with the front output splines; then place the differential into position on the frame and install the cap screws, washers, and flex-lock nuts. Tighten to specifications. Make sure the rubber boot is properly seated on the input yoke. CC900 3. Using a press, install the new bearing into the housing. CD857 CC901 NOTE: Prior to installing the seal, apply grease to the seal outside diameter. 4. Install the seal into the housing pressing evenly on the outside edge until the seal is seated. CD859 2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lubricant into the differential and install the filler plug. Tighten to specifications. 3. Install the front drive actuator with the three torx-head cap screws; then connect the wire connector to the main wiring harness. www.mymowerparts.com 6-16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AG925 AF896D 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this section). 6. Secure the upper A-arms with cap screws and lock nuts. Tighten to specifications. AF895D 9. Making sure that each caliper has the 0.76 mm (0.030 in.) spacer washers between the caliper and the knuckle, install the brake calipers. Secure with the cap screws tightened to specifications. 6 AF610D 7. Secure the lower shock eyelets with cap screws and lock nuts. Tighten to specifications. AF894D 10. Install the wheels and tighten to specifications. 11. Remove the ATV from the support stand. AF897D 8. Secure the tie rods with the lock nuts. Tighten to specifications; then install and spread the cotter pins. www.mymowerparts.com 6-17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. While holding the drive axle stationary, pull the top of the knuckle out and down until it is free of the drive axle. Drive Axles 9. Place a drain pan under the ATV to contain any oil leakage; then using a slide hammer, remove the drive axle. REMOVING REAR DRIVE AXLE 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Pump up the hand brake; then engage the brake lever lock. 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock. AF935 REMOVING FRONT DRIVE AXLE NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING NOTE: Always clean and inspect the drive axle components to determine if any service or replacement is necessary. 1. Using a clean towel, wipe away any oil or grease from the axle components. KX041 5. Remove the two brake calipers (right side only). NOTE: Do not allow the brake calipers to hang from their cable/hose. ! CAUTION The calipers should be supported. If the calipers are allowed to hang from the cable/hose, damage may occur. 6. Slide the hub out of the knuckle and set aside. 7. Remove the cap screw and lock nut securing the knuckle to the upper A-arm. Discard the lock nut. NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. www.mymowerparts.com 6-18 CD019 2. Inspect boots for any tears, cracks, or deterioration. NOTE: If a boot is damaged in any way, it must be replaced with a boot kit. 3. Inspect the gear case seals for nicks or damage. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DISASSEMBLING AXLES 1. Using a side-cutters (or suitable substitute), remove the large clamp from the boot. CD022 5. Inspect the splines of the shaft, the bearing ring, and the housing for damage. CD020 2. Wipe away excess grease to access the retaining ring. Using an awl or circlip pliers, remove the circlip. NOTE: If any damage is apparent to the splines, the bearing ring, and/or the housing, the drive axle must be replaced as an assembly. 6. Using a side-cutters (or suitable substitute), remove the small clamp from the shaft. 6 CD021 3. Using a snap ring pliers, remove the circlip securing the bearing ring to the shaft. Note the direction of the bearing for assembling purposes. CD752 NOTE: At this point if the outside boot is damaged, continue with step 7. 7. Using a side-cutters (or suitable substitute), remove both outside boot clamps from the shaft. Note the position of the different-sized clamps for assembling purposes. CD023 4. Note the difference inside each bearing ring end for assembling purposes; then remove the bearing ring. NOTE: The recess of the bearing must face toward the housing. CD751 www.mymowerparts.com 6-19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Apply 40 grams (1/3 of contents) of grease from the Grease Pack (p/n 0441-173) into the knuckles and the new outside boot. CD024 ASSEMBLING AXLES ATV-1052 NOTE: Grease Pack (p/n 0441-173) contains 120 grams of grease. The inside joint (double-offset) requires approximately 70-90 grams of grease and the outside (bell-type) requires approximately 35-55 grams. When replacing boots, use 2/3 of the pack for inside boots and 1/3 of the pack for outside boots. 1. Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly. NOTE: The boot is positioned correctly when the small end of the boot seats down into the recessed groove. ! CAUTION Do no over-fill the joint as boot damage may occur resulting in joint failure. 9. Slide the new outside boot onto the shaft with the new clamps positioned as shown. Note the different-sized clamps from removal. NOTE: The boot is positioned correctly when the small end of the boot seats down into the recessed groove. CD754 2. Using the boot clamp pliers, secure the small clamp of the inner boot. CD754 10. Using a CV Boot Clamp Tool (p/n 0444-120), secure both outside boot clamps. ! CAUTION It is important that the clamps are positioned correctly or they may loosen when in motion. www.mymowerparts.com 6-20 ATV-1048 3. Apply 80 grams (2/3 of contents) of grease from the pack into the bearing housing. 4. Install the bearing onto the shaft making sure the recess of the bearing is facing the housing. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Slide the boot over the housing; then using the boot clamp pliers, secure the boot with the clamp. CD022 ! CAUTION The bearing ring must go onto the shaft with the side without splines facing toward the small clamp of the inner boot or severe damage will result. 5. Secure the bearing ring with the circlip making sure the sharp side of the circlip faces away from the boot. CD024 8. Inspect the axle components for correct positioning of the four clamps. Also, inspect the boots for being correctly positioned on the shaft. INSTALLING REAR DRIVE AXLE 1. Slide the drive axle into place in the gear case. NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain “clipped” in place. 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. Secure the knuckle to the A-arm with a cap screw and a new lock nut. Tighten to specifications. CD023 6. Making sure the marks made during disassembling align, slide the housing over the bearing ring; then completely seat the bearing ring into the housing and install the circlip. NOTE: Pull the bearing ring out of the housing until it contacts the circlip; then slide the ring in half way. This will purge air from the housing and ensure the bearing is packed properly. 3. Place the hub into position on the axle followed by a hex nut. Tighten the hex nut finger-tight at this time. 4. If the brake calipers were removed, position them on the knuckle and secure with existing cap screws. Tighten the auxiliary brake caliper cap screws to specifications. Tighten the hydraulic brake caliper cap screws to specifications. 5. Pump up the hand brake lever; then engage the brake lever lock. 6. Tighten the hub hex nut (from step 3) to specifications; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut. CD021 www.mymowerparts.com 6-21 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the ATV from the support stand and release the brake lever lock. 9. Check the front differential oil level and add oil as necessary. CD027 7. Install the wheel. Tighten to specifications. 8. Remove the ATV from the support stand and release the brake lever lock. INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steering knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tightened to specifications. 2. Place the brake hose into position on the upper A-arm; then secure the lower shock eyelet to the A-arm with a cap screw and a new lock nut. Tighten to specifications. 3. Secure the tie rod to the steering knuckle with a new lock nut. Tighten securely; then install and spread a new cotter pin. 4. Slide the hub w/brake disc into position in the steering knuckle followed by a washer and hex nut. Tighten finger-tight at this time. CF113A Rear Gear Case REMOVING 1. Remove the left-side rear A-arms (see Rear A-Arms in Section 7). 2. Remove both of the rear drive axles (see Drive Axles in this section). 3. Remove the four cap screws securing the engine output shaft to the rear gear case input flange. 5. Install the brake caliper on the steering knuckle. Tighten to specifications; then pump up the hand brake lever and engage the brake lever lock. 6. Tighten the hub hex nut (from step 4) to specifications; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut. CD028 4. Remove the two cap screws and lock nuts securing the rear gear case to the frame; then remove the gear case through the left side. CD027 7. Install the wheel and tighten to specifications. www.mymowerparts.com 6-22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF960A AT THIS POINT For servicing the input shaft, pinion gear, needle bearing, and axle seal, see Front Differential in this section. KX041 3. Remove the flange nut securing the hub. 4. Remove the brake caliper. INSTALLING 1. Slide the gear case into position through the left side of the frame; then secure it to the frame with cap screws and lock nuts. Tighten to specifications. NOTE: If a new gear case is being installed, tighten the cap screws to 5.1-6.3 kg-m (37-45.5 ft-lb). 2. Secure the engine output shaft to the rear gear case input flange with three cap screws (coated with red Loctite #271) and lock nuts. Tighten to specifications. PR243A 5. Remove the hub assembly. 6. Remove the four cap screws securing the brake disc. 3. Install the rear drive axles (see Drive Axles in this section). CLEANING AND INSPECTING 4. Install the left-side rear A-arms (see Rear A-Arms in Section 7). NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. Hub REMOVING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the cotter pin from the nut. 1. Clean all hub components. 2. Inspect all threads for stripping or damage. 3. Inspect the brake disc for cracks or warping. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. INSTALLING 1. Secure the brake disc to the hub with the four cap screws coated with blue Loctite #243. Tighten to specifications. 2. Apply grease to the splines in the hub. NOTE: During assembly, new cotter pins should be installed. www.mymowerparts.com 6-23 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Tighten the hub nut (from step 4) to specifications; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut. PR291 3. Install the hub assembly onto the shaft. CD008 7. Install the wheel and tighten to specifications. CD009 4. Secure the hub assembly with the nut. Tighten only until snug. 5. Secure the brake caliper to the knuckle with the two cap screws. Tighten the auxiliary caliper to specifications. Tighten the hydraulic caliper to specifications. CD006 8. Remove the ATV from the support stand. Hydraulic Brake Caliper NOTE: The brake caliper is a non-serviceable component; it must be replaced as an assembly (see Section 2). PR243A www.mymowerparts.com 6-24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION 7 TABLE OF CONTENTS www.mymowerparts.com Suspension ............................................................. 7-2 Shock Absorbers ..................................................... 7-2 Front A-Arms ........................................................... 7-3 Rear A-Arms ........................................................... 7-5 Wheels and Tires .................................................... 7-7 7-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension NOTE: Critical torque specifications are located in Section 10. Shock Absorbers AF626D REMOVING 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension. 4. Compress the shock absorber spring, remove the retainer, and remove the spring. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the two cap screws and nuts securing each front shock absorber to the frame and the upper A-arm. Account for bushings and sleeves from each. AF730D CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all shock absorber components in parts-cleaning solvent. AF605D ! CAUTION Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur. 3. Remove the two cap screws and nut securing each rear shock absorber to the frame and lower A-arm. Account for bushings and sleeves from each. www.mymowerparts.com 7-2 2. Inspect each shock rod for nicks, pits, rust, bends, and oily residue. 3. Inspect all springs, spring retainers, shock rods, sleeves, bushings, shock bodies, and eyelets for cracks, leaks, and bends. INSTALLING 1. Place the shock absorber spring over the shock absorber, compress the spring, and install the retainer. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place bushings and sleeves (where appropriate) into shock eyelet; then install shock with two cap screws and nuts. Tighten all nuts to specifications. ! CAUTION Do not tighten the nuts beyond the 4.8 kg-m (35 ft-lb) specification or the shock eyelet or mount WILL be damaged. NOTE: The rear shock absorber-to-lower A-arm torque factor is 2.8 kg-m (20 ft-lb). CD007 5. Remove the hub assembly. 3. Remove the ATV from the support stand. 6. Remove the cotter pin and slotted nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle. Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the cotter pin from the nut. Discard the cotter pin. AF618D 7. Remove the cap screws securing the ball joints to the knuckle. ! CAUTION Support the knuckle when removing the cap screws or damage to the threads will occur. CD008 3. Remove the nut securing the hub. 4. Remove the brake caliper. Account for two cap screws and two 0.76 mm (0.030 in.) spacer washers. AF628D 8. Tap the ball joints out of the knuckle; then remove the knuckle. 9. Remove the lower shock absorber eyelet from the upper A-arm. www.mymowerparts.com 7-3 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Remove the cap screws securing the A-arms to the frame. AF616D AF610D 11. Remove the circlip from the ball joint; then remove the ball joint from the A-arm. 2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten at this time. AF610D AF616D CLEANING AND INSPECTING 3. Route the brake hose through the upper A-arm shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all A-arm components in parts-cleaning solvent. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes. 3. Inspect the A-arm for bends, cracks, and worn bushings. 4. Inspect the ball joint mounting holes for cracks or damage. 5. Inspect the frame mounts for signs of damage, wear, or weldment damage. INSTALLING 1. Apply green Loctite #609 to the entire outside diameter of the ball joint; then install the ball joint into the A-arm and secure with the circlip. www.mymowerparts.com 7-4 DE054A 4. Secure the lower eyelet of the shock absorber to the upper A-arm. Tighten nut to specifications. 5. Secure the A-arm assemblies to the frame mounts (from step 2). Tighten the cap screws to specifications. ! CAUTION Do not tighten the nut beyond the 4.8 kg-m (35 ft-lb) specification or the shock eyelet or mount WILL be damaged. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the knuckle assembly onto the ball joints and secure with cap screws. Tighten to specifications. 10. Secure the brake caliper to the knuckle with the two cap screws making sure the two 0.76 mm (0.030 in.) spacer washers are positioned between the caliper and the knuckle. Tighten to specifications. AF628D 7. Install the tie rod end and secure with the nut. Tighten to specifications; then install a new cotter pin and spread the pin to secure the nut. NOTE: During assembly, new cotter pins should be installed. CD007 11. Secure the hub nut (from step 9) to the shaft/axle. Tighten to specifications. 12. Install a new cotter pin and spread the pin to secure the nut. AF618D 8. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. CD008 13. Install the wheel and tighten to specifications. 14. Remove the ATV from the support stand. Rear A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING CD009 9. Secure the hub assembly with the nut. Tighten only until snug. www.mymowerparts.com Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Pump up the hand brake; then engage the brake lever lock. 7-5 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock. 5. Remove the caliper (right side only). NOTE: Do not allow the brake calipers to hang from their cable/hose. 6. Remove the cap screws and lock nut securing the shock absorber to the frame and lower A-arm; then remove the shock absorber. 7. Remove the cap screws securing the boot guard to the lower A-arm. 3. Inspect the frame mounts for signs of damage, wear, or weldment damage. INSTALLING 1. Install the A-arm assemblies into the frame mounts and secure with the cap screws and new lock nuts. Only finger-tighten at this time. 2. Slide the knuckle onto the drive axle and into position on the A-arms; then secure the knuckle to the A-arms with cap screws and new lock nuts. Tighten to specifications. 3. Tighten the hardware securing the A-arms to the frame mounts (from step 1) to specifications. 4. Apply grease on the drive axle splines; then install the hub assembly onto the drive axle. AF934 8. Slide the hub out of the knuckle and set aside. CD009 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Discard the lock nuts. NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. 10. Remove the cap screws and lock nuts securing the A-arms to the frame; then remove the A-arms. 5. Secure the hub assembly with the nut. Tighten only until snug. 6. Secure the brake caliper to the knuckle with the two cap screws (right side only). Tighten the caliper to specifications. NOTE: Ensure that the brake hose is properly routed and secured to the upper A-arm. NOTE: If removing the upper right A-arm, it will be necessary to disconnect the brake hose from the A-arm. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all A-arm components in parts-cleaning solvent. 2. Inspect the A-arm for bends, cracks, and worn bushings. www.mymowerparts.com 7-6 DE054A 7. Compress the hand brake lever and engage the brake lever lock; then secure the hub nut (from step 5) to the drive axle. Tighten to specifications. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install a new cotter pin and spread the pin to secure the nut. TIRE SIZE ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed in the General Specifications (see Section 1). Do not under any circumstances substitute tires of a different type or size. ! WARNING CD008 9. Secure the shock absorber to the frame with a cap screw and new lock nut. Tighten to specifications. 10. Secure the shock absorber to the lower A-arm with a cap screw and new lock nut. Tighten to specifications. 11. Secure the boot guard to the lower A-arm with the two cap screws. Tighten securely. 12. Install the wheel and tighten to specifications. 13. Remove the ATV from the support stand. Do not mix tire tread patterns. Use the same pattern type on front and rear. Failure to heed warning could cause poor handling qualities of the ATV and could cause excessive drive train damage not covered by warranty. TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0.35 kg/cm² (5.0 psi). REMOVING 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Wheels and Tires Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the wheels. KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. NOTE: Keep left-side and right-side wheels separated for installing them on their proper sides. Machine Screw Brake Disc Wheel Hub - Front Hub Stud Cotter Pin Hex Nut Wheel Mounting Nut Tire - Front Valve Stem Valve Stem Cap Wheel Hub - Rear Wheel Tire - Rear CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean the wheels and hubs with parts-cleaning solvent. 2. Clean the tires with soap and water. 0739-534 3. Inspect each wheel for cracks, dents, or bends. 4. Inspect each tire for cuts, wear, missing lugs, and leaks. INSTALLING 1. Install each wheel on its hub. www.mymowerparts.com 7-7 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the tires for damage, wear, or punctures. ! WARNING Do not operate the ATV if tire damage exists. NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern. CD006 NOTE: Make sure each wheel is installed on its proper hub as noted in removing (the “rotation arrow” (if applicable) must indicate forward direction of rotation). 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Section 8). 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, deceleration, and braking. NOTE: If pulling is noted, measure the circumference of the front and rear tires on the pulling side. Compare the measurements with the tires on the opposite side. If pulling is noted during braking only, check and adjust the brakes as necessary and recheck operation (see Section 2). 5. Increase the air pressure in the tires with the smallest circumference measurement until all tires are equal in circumference. AF612D 2. Tighten to specifications. CHECKING/INFLATING 1. Using an air pressure gauge, measure the air pressure in each tire. Adjust the air pressure as necessary to meet the recommended inflation pressure. CD005 www.mymowerparts.com 7-8 6. Repeat steps 4-5 as necessary to ensure proper handling. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS www.mymowerparts.com Steering/Frame........................................................ 8-2 Steering Post/Tie Rods ........................................... 8-2 Handlebar Grip ........................................................ 8-5 Steering Knuckles ................................................... 8-6 Measuring/Adjusting Toe-In..................................... 8-8 Front Rack ............................................................... 8-9 Front Bumper Assembly ........................................ 8-10 Front/Rear Body Panel .......................................... 8-10 Front Body Panel/Side Panels (TBX/TRV/500/650 H1/700 EFI) ........................ 8-13 Footrests ............................................................... 8-17 Belly Panel ............................................................ 8-18 Exhaust System .................................................... 8-18 Rear Body Panel/Rack .......................................... 8-19 Side Storage Box (TBX Models) ........................... 8-20 Cargo Box (TBX Models) ...................................... 8-21 Adjusting Headlight ............................................... 8-22 Taillight Assembly.................................................. 8-22 Seat ....................................................................... 8-22 8-1 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame NOTE: Critical torque specifications are located in Section 10. Steering Post/ Tie Rods CD759 NOTE: Some components may vary from model to model. The technician should use discretion and sound judgment. 2. Remove the reinstallable rivets securing the radiator access cover and remove the cover. CD666 3. Remove four reinstallable rivets securing the steering post cover and remove the cover. KEY 1. 2. 3. 4. 5. Cap Screw Cap Shoulder Screw Housing Cap Housing (Lower) 6. Housing (Upper) 7. 8. 9. 10. Steering Post Cap Screw Bearing Flange Bearing w/Oil Seal 11. Washer 12. Cap Screw 13. Tie Rod Assy 14. 15. 16. 17. 18. Ball Joint (Left) Nut (Left) Tie Rod Nut (Right) Ball Joint (Right) 19. Lock Nut 20. Cotter Pin 0739-774 REMOVING 1. Remove the ignition switch retaining ring; then remove the reinstallable rivets securing the instrument pod to the mounting bracket and remove the pod. www.mymowerparts.com 8-2 CD667 4. Unlatch the storage compartment lid; then slide the storage compartment cover assembly forward and lift off. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD669 5. Remove the storage compartment. CD760 8. Using a suitable lift stand, raise the ATV enough to remove the front wheels; then remove the left-side and right-side splash panels. CD671 6. Remove the four cap screws securing the handlebar caps and speedometer bracket to the steering post; then move the handlebar and speedometer out of the way. Account for four handlebar caps. CD685 9. Remove the cotter pins and slotted nuts from the inner and outer tie rod ends; then remove the tie rods from the steering post arm and the left-side and right-side steering knuckles. 8 CD762 7. Remove two cap screws securing the upper steering post bearing to the frame. Account for two bearings and two housings. AF778D www.mymowerparts.com 8-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Inspect the handlebar tube for cracks, wear, or unusual bends. 8. Inspect the handlebar grips for damage or wear. INSTALLING 1. Place the steering post into position; then secure the lower bearing flange to the frame with two cap screws. Tighten to specifications. KX039 10. Remove two cap screws securing the lower steering post bearing flange to the frame; then remove the steering post. AL600D 2. Place the upper steering post bearings into the housings; then position on the steering post and secure the housings to the frame with two cap screws. Tighten to specifications. AL600D CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. CD760 ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deterioration. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 6. Inspect the bearing halves, bearing caps, and bearing housings for cracks or wear. www.mymowerparts.com 8-4 3. Install the tie rods and secure with the slotted nuts. Tighten to specifications; then install new cotter pins. NOTE: If the slots do not align with the holes in the tie rod ends, tighten the nuts just enough to allow installation of the cotter pins. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF778D CD677 4. Install the splash panels; then install the front wheels and tighten to specifications using a crisscross pattern. 5. Lower the ATV and place the handlebar and caps into position on the steering post; then position the speedometer on top of the caps and secure with the four cap screws. Tighten to specifications. 6. Install the storage compartment box; then attach the storage compartment cover assembly by engaging the lugs into the slots and sliding rearward. Lock the storage compartment lid to hold the assembly in place. CD676 8. Install the steering post access cover and secure with four reinstallable rivets; then install and secure the radiator access cover. Handlebar Grip REMOVING 1. Remove the plug from the head of the rivet. 2. Using a 1/8-in. drill bit, drill out the rivet. CD671 3. Using compressed air between the grip and the handlebar, twist the grip back and forth until it slides free of the handlebar. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the grip for wear, cuts, or cracks. 2. Inspect the grip for deterioration. CD670 7. Place the instrument pod into position over the speedometer; then secure with two reinstallable rivets and the ignition switch locking ring. www.mymowerparts.com 8-5 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING NOTE: Before installing a grip, use contact spray or alcohol to clean the inside of the grip and the handlebar of glue residue, oil, or any other contaminant. 1. Apply a liberal amount of Handlebar Grip Adhesive to the inside of the grip. 2. Align the rivet hole in the grip with the rivet hole in the handlebar; then align the notch (inside the grip) with the slot in the handlebar and slide the grip onto the handlebar until it is fully seated. PR287A 3. Wipe off any excess glue; then secure the grip with a new rivet. 4. Install the plug on the head of the rivet. Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the wheel cap from the hub; then remove the cotter pin from the nut. 3. Remove the nut securing the hub. 4. Remove the brake caliper. PR288 ! CAUTION Use extreme care when removing the bearing. If the bearing is allowed to fall, it will be damaged and will have to be replaced. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all knuckle components. 5. Remove the hub assembly. 2. Inspect the bearing for pits, gouges, rusting, or premature wear. 6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. 3. Inspect the knuckle for cracks, breaks, or porosity. 7. Remove the two cap screws securing the ball joints in the knuckle. 4. Inspect threads for stripping or damage. 8. Tap the ball joint end out of the knuckle; then remove the knuckle. 9. Remove the snap ring from the knuckle; then remove the bearing. www.mymowerparts.com 8-6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ASSEMBLING AND INSTALLING 1. Install the bearing; then install the snap ring making sure it seats into the knuckle. PR290A 5. Install the hub assembly onto the splines of the shaft. PR287A 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to specifications. 6. Secure the hub assembly with the nut. Tighten only until snug. PR257 7. Secure the brake caliper to the knuckle with the two cap screws. Tighten to specifications. AF760D 3. Install the tie rod end and secure with the nut. Tighten to specifications; then install a new cotter pin and spread the pin. NOTE: During assembling, new cotter pins should be installed. 8 PR264A 8. Pump the hand brake lever; then engage the brake lever lock. 9. Secure the hub nut (from step 6) to the shaft. Tighten to specifications. AF759D 4. Apply a small amount of grease to the hub splines. 10. Install a new cotter pin and spread the pin to secure the nut. 11. Install the wheel; then using a crisscross pattern, tighten to specifications. www.mymowerparts.com 8-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD012A CD006 12. Remove the ATV from the support stand. Measuring/Adjusting Toe-In 5. Adjust the handlebar direction until the two measurements are equal; then secure the handlebar to the rear rack using tie-down straps. NOTE: Care must be taken not to allow the handlebar to turn while securing it. 1. Thoroughly wash the ATV to remove excess weight (mud, etc.). 2. Refer to the specifications and ensure the tires are properly inflated to the recommended pressure. NOTE: Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur. CD014 6. Measure the distance from the inside of each front rim to the lower frame tube. CD005 3. Place the ATV in a level position taking care not to push down or lift up on the front end; then turn the handlebar to the straight ahead position. NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (without an operator but with Arctic Cat approved accessories). 4. Measure the distance from the outside edge of each handlebar grip to the seat catch brackets. www.mymowerparts.com 8-8 AF785D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF786D NOTE: The distances from the inside rims to the frame tubes should be equal. If the measurements are equal, proceed to step 8; if the measurements are not equal, proceed to step 7. 7. To make the measurements equal, loosen the appropriate tie rod jam nuts and adjust accordingly; then proceed to step 8. AF789D 9. Measure the distance between the marks (at a height parallel to the belly panel) at the front side; then record the measurement. 10. Push the ATV forward until the marks are parallel to the belly panel on the back side; then measure the distance between the marks. 11. The difference in the measurements must show 3.2-6.4 mm (1/8-1/4 in.) toe-in (the front measurement 3.2-6.4 mm (1/8-1/4 in.) less than the rear measurement). 12. If the difference in the measurements is not within specifications, adjust both tie rods equally until within specifications. NOTE: Prior to locking the jam nuts, make sure the ball joints are at the center of their normal range of motion and at the correct angle. AF617D 8 733-559A AF778D NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to disturb the handlebar position. 8. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the belly panel). Front Rack REMOVING 1. Remove the two cap screws and lock nuts securing the front fender panel. 2. Remove the cap screws and lock nuts securing the rack to the frame. www.mymowerparts.com 8-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the front rack from the ATV. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all rack components with parts-cleaning solvent. 2. Inspect all welds for cracking or bending. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals and/or reflectors. INSTALLING 1. Place the rack into position on the frame and front fender panel. Install the cap screws and lock nuts and finger-tighten only. 2. Install the two cap screws and lock nuts securing the rack to the fenders. Tighten all hardware securely. Front/Rear Body Panel REMOVING 1. Remove the seat; then remove the battery cover/tool tray. 2. Remove the negative battery cable from the battery; then remove the positive cable. Remove the vent hose; then remove the battery. ! CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 3. Remove four reinstallable rivets securing the storage compartment to the body; then remove the storage compartment and the steering post cover. Front Bumper Assembly REMOVING 1. Remove the two flange bolts and lock nuts securing the upper bumper supports to the bumper. CF145A 2. Remove the through-bolt and lock nut securing the bumper to the frame; then remove the bumper. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all bumper components with parts-cleaning solvent. 2. Inspect all welds for cracking or bending. INSTALLING 1. Place the front bumper assembly into position and install the through-bolt. Start the lock nut and finger-tighten only. 2. Install the two flange bolts and lock nuts on the upper supports. Tighten all hardware securely. www.mymowerparts.com 8-10 CF143A 4. Remove the left-side and right-side fender splash panels; then remove one press-in fastener and one reinstallable rivet from the left side and right side of the air-intake splash shroud. Do not remove the shroud. 5. Disconnect the four headlight connectors and the taillight/brakelight connector from the sockets. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF135A CF201A 6. Remove the shift knob; then remove the nut and axle pivot bolt securing the lever to the shift lever axle. Remove the shift lever. Account for the two O-rings on the axle bolt and one spring. CF160A 8. Remove the two cap screws and lock nuts securing the left foot peg and remove the foot peg. CD779 8 CD782 CD780A 7. Remove the front and rear racks; then remove the two body bolts adjacent to the air filter housing and two push nuts located behind the grille. 9. Remove eight cap screws and lock nuts and one reinstallable rivet securing the right-side footwell to the fenders. 10. Lift and support the rear of the body to allow access to the torx-head cap screws securing the front and rear body sections together; then remove six self-locking nuts (three from each side). Remove the rear body panel; then remove the front one. www.mymowerparts.com 8-11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Making sure the body mounting grommets are in place, position the front and rear racks; then install the eight flanged cap screws and lock nuts. Do not tighten at this time. CF213A NOTE: To aid in removing the body without separating the front and rear panels, it is advisable to have an assistant help with lifting and guiding the body clear of the handlebar. CD679A CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all fender components with part-cleaning solvent and soap and water. 2. Inspect fenders for cracks and/or loose rivets. 3. Inspect for any missing decals. CD690A INSTALLING 1. Place the body assembly into position on the ATV. NOTE: If the front and rear body panels have been separated, proceed to step 2; if the panels have not been separated, proceed to step 3. 4. Install four rack-to-body machine screws and lock nuts on the front and rear racks, two push nuts behind the grille, and two body bolts adjacent the air filter housing; then tighten all fasteners (from step 3 and 4) securely. 2. Install the torx-head cap screws and lock nuts securing the front and rear body panels together. Tighten securely. CF160A CF213A www.mymowerparts.com 8-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Connect the positive battery cable; then connect the negative battery cable. Tighten the battery terminal cap screws securely. 11. Install the battery cover/tool tray; then install the seat. Make sure the seat locks securely. Front Body Panel/ Side Panels (TBX/TRV/500/650 H1/700 EFI) CF201A 5. Install eight cap screws and lock nuts securing the right-side footwell to the front and rear fenders; then place the left-side foot peg into position and secure with two cap screws and lock nuts. Tighten securely. 6. Place the storage compartment into position; then install the steering post cover. Secure with the reinstallable rivets. REMOVING 1. Remove the reinstallable rivets securing the radiator access cover and remove the cover; then remove four reinstallable rivets securing the steering post cover and remove the cover. CD666 CF145A 8 CD667 CF134A 7. Place the shift lever into position making sure the spring is installed; then secure with the axle pivot bolt and lock nut. 2. Unlock the storage compartment lid; then slide the storage compartment cover assembly forward and lift off the storage compartment. 8. Install the shift knob and the left-side and right-side splash panels; then reconnect the headlights. Tighten all fasteners securely. 9. Place the battery into position in the battery box; then connect the vent hose. www.mymowerparts.com 8-13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD669 CD679A 3. Remove the storage compartment box; then remove the seat. CD680 CD671 4. Remove the ignition switch lock collar and two reinstallable rivets securing the instrument pod; then remove the instrument pod. 6. Remove three reinstallable rivets securing the right side panel; then remove two torx-head cap screws securing the rear of the front panel to the frame. CD683A CF207A 5. Remove four machine screws and lock nuts securing the front rack to the frame; then remove the front rack. Account for four grommets and four bushings. CD684A www.mymowerparts.com 8-14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the torx-head cap screws and nylon ties securing the left-side and right-side splash panels; then remove the panels. CD779 CD685 8. Remove one shoulder screw and four plastic rivets on each side to separate the front panel lower fenders from the left-side and right-side footwells. CD780A 10. Disconnect four headlight connectors and secure the wires out of the way; then disconnect the wires to the front accessory plug. CD691 8 CD681 11. Rotate the handlebar to the full-left position; then lift and slide the panel to the rear and lift the rear up to clear the handlebar. CD682 9. Remove the shift knob retaining pin and remove the shift knob; then remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. www.mymowerparts.com 8-15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD765A CD681 NOTE: It may be necessary to rotate the body panel to the right to align the opening with the handlebar. 3. Make sure the four rubber grommets and bushings are in place; then place the front rack into position and secure with four machine screws and flange nuts. Tighten securely. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all fender components with part-cleaning solvent and soap and water. 2. Inspect fenders for cracks and/or loose rivets. 3. Inspect for any missing decals. INSTALLING CD679A 1. Rotate the handlebar to the full-left position; then place the front body panel over the handlebar and rotate and lower into position. 4. Install one machine screw and flange nut and four plastic rivets on each side to secure the front fenders to the footwells. Tighten the flange nuts securely. NOTE: If the footwells have been removed, see Footrests in this section. 5. Install four cap screws securing the front body panel to the frame and rear panel. CD765 2. Connect the headlight connectors to the appropriate headlights and the front accessory plug wires to the accessory plug. CD684A 6. Install the shift lever spring, shift lever, and pivot axle; then tighten the axle nut securely. www.mymowerparts.com 8-16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD779 CD670A 7. Install the left-side and right-side splash panels and tighten the cap screws securely. Install new nylon ties in the appropriate locations. 10. Install the steering post cover and secure with the reinstallable rivets; then install and secure the radiator access panel. 8. Install the instrument pod and ignition switch; then secure with two reinstallable rivets and the ignition switch lock collar. 11. Install the left and right side panels and secure with reinstallable rivets. CD683A CF207A 9. Set the storage compartment box into position; then install the storage compartment cover making sure the mounting lugs engage the slots. Slide rearward to secure and lock by engaging the lid lock. Footrests REMOVING 1. Remove the machine screws and flange nuts securing the front and rear fenders to the footwells. CD671 CD691A www.mymowerparts.com 8-17 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the cap screws securing the foot pegs to the footrests; then remove the foot pegs and footwells. Belly Panel REMOVING/INSTALLING 1. Remove the machine screws and shoulder washers securing the belly panel to the underside of the frame; then remove the belly panel. 2. Place the belly panel into position on the underside of the frame; then install the machine screws and shoulder washers. Tighten securely. CD782 3. Remove the cap screws and flange nuts securing the footrests to the frame; then remove the footrests. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muffler/exhaust pipe juncture. 1. Clean the footrest in parts-cleaning solvent. 2. Inspect the footrest weldments for cracks or unusual bends. 3. Inspect all tubing for cracks or unusual bends. INSTALLING 1. Secure the footrests to the frame with four cap screws and two flange nuts; then tighten securely. 2. Place the footwells onto the footrests; then put the foot pegs in position and secure with two cap screws. CF138A 2. Slide the muffler rearward to clear the mounting lugs and remove the muffler. INSPECTING MUFFLER NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler. NOTE: For additional details on cleaning the muffler/spark arrester, see Section 2. CD782 3. Install the machine screws and flange nuts securing the front and rear fenders to the footwells. www.mymowerparts.com 8-18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING MUFFLER 1. Place the muffler into position engaging the mounting lugs into the grommets; then slide the muffler forward. 2. Install the two exhaust springs. Rear Body Panel/Rack CD687A REMOVING 1. Remove four machine screws and flanged nuts securing the rear rack; then remove the rear rack. Account for four bushings. 4. Disconnect the battery (negative cable first); then remove the battery. CD688 CD690A 2. Remove one shoulder screw and lock nut and three plastic rivets (on each side) securing the rear body panel to the footwells. 5. Disconnect the taillight/brakelight; then remove the gas tank cap and lift off the rear body panel. Install the gas tank cap. NOTE: If the front body panel has not been removed, the left-side and right-side panels and the two machine screws must be removed (see Front Body Panel/Side Panels in this section). CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all rear body panel components with parts-cleaning solvent and soap and water. CD691A 3. Remove two machine screws securing the battery cover and remove the cover. 2. Inspect side panels and rear body panel for cracks and loose rivets. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals. www.mymowerparts.com 8-19 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Remove the gas tank cap and set the rear body panel in position; then install the cap and connect the taillight/brakelight connector. 2. Place the rear rack in position with four bushings and secure with four machine screws and flanged nuts. Tighten securely. NOTE: If the front body panel has not been installed, see Front Body Panel/Side Panels in this section. 6. Place the seat into position making sure it locks securely. Side Storage Box (TBX Models) REMOVING 1. Rotate the cargo box latch handle (located on the left and right sides between the cargo box and the rear tire) and fully raise the cargo box. 2. Pull the seat lock lever forward (located below the right side of the seat), raise the front end of the seat, and slide it forward and off the ATV. CD690A 3. Install one shoulder screw and three plastic rivets (on each side) to secure the front of the rear body panel to the footwells. 3. Remove the two cap screws (located inside the side storage box) securing the box to the footrest. 4. Remove the screw securing the box to the side panel. 5. Remove cap screws (A and B) securing the box to the frame. CD691 4. Place the battery into the battery box; then connect the battery (positive cable first) and secure with the battery cover. CD045A CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all side storage box components with soap and water. CD687A 5. Secure the front and rear panels with two machine screws; then install the left and right side panels. www.mymowerparts.com 8-20 2. Inspect the box for cracks, tears, and loose mounting hardware. 3. Inspect the box hatch O-ring seals for cuts or tears. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Place the side storage box into position on the frame; then secure with the two cap screws (A and B). Tighten cap screws to specifications. 3. Remove the two cap screws and lock nuts securing the cargo box to the frame; then remove the cargo box and discard the lock nuts. CD122 CD045A 2. Secure the box to the side panel with the existing screw. 3. Secure the box to the footrest with existing hardware. Tighten securely. 4. Install the seat. 5. Lower the cargo box and press down firmly on the front of the box. The cargo box will automatically lock into position. NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all cargo box components with soap and water. 2. Inspect the cargo box for cracks, tears, and loose mounting hardware. Cargo Box 3. Inspect the welds of the cargo box frame for cracking or bending. (TBX Models) 4. Inspect the cargo box gate latches for smooth operation. REMOVING 1. Rotate the cargo box latch handle (located on the left and right sides between the cargo box and the rear tire) and fully raise the cargo box. INSTALLING 1. Place the cargo box into position on the frame. Secure with cap screws and new lock nuts. Tighten to specifications. CD771 2. Remove the nut from the lower end of the box lift support. CD122 www.mymowerparts.com 8-21 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. While an assistant holds the cargo box in the raised position, secure the lower end of the box lift support to the frame with the cap screw and nut. 3. Lower the cargo box and press down firmly on the front of the box. It will automatically lock into position. INSTALLING 1. Place the assembly into position on the frame and secure with torx-head cap screws and any washers. 2. Tighten the cap screws securely. 3. Route the wiring harness over the rear frame; then connect the three-prong connector. Adjusting Headlight Seat The headlights can be adjusted vertically and horizontally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming. To check/adjust headlight beam, see Section 2. ! WARNING Do not operate the ATV unless the headlight beam is adjusted properly. An incorrectly adjusted beam will not provide the operator the optimum amount of light. Taillight Assembly REMOVING 1. Unplug the three-prong connector and free the taillight wiring harness from the frame. NOTE: Some components may vary from model to model. The technician should use discretion and sound judgment. REMOVING/INSTALLING 1. To remove the seat, lift up on the latch release (located at the rear of the seat). Raise the rear of the seat and slide it rearward. 2. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on the rear of seat. The seat should automatically lock into position. REMOVING/INSTALLING (TRV) 1. To remove the rear seat, pull the two latch handles to the rear and rotate them to the vertical position. 2. Remove the torx-head cap screws securing the taillight assembly to the frame. Account for any washers. 3. Remove the taillight assembly. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect wiring harness, three-prong connector, lens, base, cap screws, and socket for damage. 2. Inspect all wires for corroding, pinching, and cracking. 3. Inspect the bulb for wattage, voltage, and proper operation. www.mymowerparts.com 8-22 CF226 2. Lift the rear of the seat up; then pull slightly to the rear and lift the seat off the mountings. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Lock the seat into position by pulling the two latch handles to the rear and rotating them to the horizontal position. CF227A 3. To lock the seat into position, engage the two front mounting lugs into the mounting rack; then holding down firmly on the front of the seat, push the seat forward until the rear tabs engage the rear mounting latches. CF226A NOTE: The rear seat must be removed prior to removing the front seat. 5. To remove the front seat, pull the seat lock lever up (located at the rear of the seat). Raise the rear end of the seat and slide it rearward. 6. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on rear of seat. The seat should automatically lock into position. CF229A 8 www.mymowerparts.com 8-23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS 9 TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ......... 9-2 Throttle Control ....................................................... 9-3 Gearshift Pedal (Manual Transmission)................... 9-5 Drive Selector.......................................................... 9-5 Front Differential Lock ............................................. 9-5 Shift Lever ............................................................... 9-5 Speedometer/Tachometer/LCD............................... 9-6 www.mymowerparts.com 9-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the pivot pin hole in the housing; then lay it aside leaving the switch and wiring harness connected. Hand Brake Lever/ Master Cylinder Assembly NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a container. Remove the reservoir cover; then open the bleeder valve. Allow the brake fluid to drain completely. NOTE: Compressing the brake lever several times will quicken the draining process. BC205 5. Remove the clamp screws securing the brake housing to the handlebar; then remove the assembly from the handlebar. AF637D 2. Place an absorbent towel around the connection to absorb brake fluid. Remove the banjo-fitting from the master cylinder. Account for two crush washers and a banjo-fitting bolt. DE058A INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the pin securing the brake lever for wear. 2. Inspect the brake lever for elongation of the pivot hole. 3. Inspect the reservoir for cracks and leakage. DE059A ! CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV. 3. Remove the circlip and pivot pin securing the brake lever to the master cylinder housing; then remove the brake lever and set aside. www.mymowerparts.com 9-2 4. Inspect the banjo-fitting for cracks and deterioration and the condition of the fittings (threaded and compression). 5. Inspect the brakelight switch for corrosion, cracks, missing or broken mounting tabs, or broken and frayed wiring. NOTE: If the brakelight switch is determined to be not serviceable, see Section 5. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. Throttle Control REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar. 2. Slide the grommet out of the lower half of the throttle control; then remove the cable from the actuator arm. DE058A 2. Using two new crush washers, connect the banjo-fitting to the master cylinder; then secure with the banjo-fitting bolt. AF676D 3. Remove the cap screw, lock washer, and washer securing the actuator arm to the throttle control lever. DE059A 3. Gently press the brakelight switch into the housing (left to right) until the mounting tabs snap into the four locating holes; then install the brake lever, pivot pin, and circlip. AF677D 4. Remove the actuator arm and account for a bushing. Note the position of the return spring for installing purposes. BC206 4. Bleed the brake system (see Section 2). www.mymowerparts.com 9-3 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF678D AF682D 2. Rotate the adjuster sleeve until 0.5-1.0 mm (0.02-0.04 in.) is attained. INSTALLING 1. Place the return spring into the throttle control; then place the bushing and actuator arm into position. Secure with the cap screw, lock washer, and washer. AL611D 3. Secure the adjustment by tightening the jam nut; then slide the boot over the jam nut. AF679D 2. Using a pair of needle-nose pliers, place the spring into position on the actuator arm. 0732-412 AF680D 3. Place the two halves of the throttle control onto the handlebars and secure with the two machine screws. ADJUSTING 1. Slide the boot back to reveal the jam nut; then loosen the jam nut. www.mymowerparts.com 9-4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Gearshift Pedal Do not attempt to either engage or disengage the front differential while the ATV is moving. (Manual Transmission) The gearshift pedal is attached to a ratchet mechanism in the transmission. Each time a gear is selected, the gearshift pedal will return to its normal position ready to select the next gear. To return to neutral, press down repeatedly (once for each gear) on the front of the pedal. Shift into gears by pressing down on the back of the pedal once for each gear. The ratchet mechanism makes it impossible to upshift or downshift more than one gear at a time. Front Differential Lock Certain ATV models are equipped with a front differential lock. The front differential lock allows the operator to mechanically lock the differential to apply equal power to both front wheels. To engage the front differential lock, rotate the handle fully clockwise to LOCK; to disengage the front differential lock, rotate the handle fully counterclockwise to UNLOCK. ATV0078C Drive Selector KX016A To adjust the differential lock cable, see Section 2. The automatic drive selector allows the operator to operate in either 2-wheel drive (rear wheels) or 4-wheel drive (all wheels). For normal riding on flat, dry, hard surfaces, 2-wheel drive should be sufficient. In situations of aggressive trail conditions, 4-wheel drive would be the desired choice. To either engage or disengage the front wheels, move the switch to the 4WD position or to the 2WD position. Shift Lever REMOVING 1. Remove the E-clip securing the shift rod to the engine shift arm. 2. Remove two cap screws, two self-tapping screws, and three nylon ties securing the left-side splash panel and remove the panel. 3. Remove the axle and nut securing the shift lever to the upper shift arm; then remove the shift lever. Account for a spring and two O-rings. 4. Using two open-end wrenches, remove the lock nut securing the shift rod to the upper shift arm. Remove the shift rod and discard the lock nut. 738-422A NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. www.mymowerparts.com 9-5 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Place the shift rod into position on the engine shift arm and secure with the existing E-clip. 2. Using a new lock nut (B), secure the shift rod to the upper shift arm; then using two open-end wrenches, tighten securely. Speedometer/ Tachometer/LCD REPLACING To replace the speedometer, use the following procedure. 1. Remove the two reinstallable rivets securing the instrument pod; then remove the ignition switch retaining ring. 2. Remove the two nuts securing the mounting studs; then remove the speedometer and disconnect the multi-pin connector. 3. Mount the speedometer and secure with the two nuts; then connect the multi-pin connector. AF941A 3. Place the spring into position between the upper shift arm and shift lever; then making sure the O-rings are in place on the axle, secure the shift lever to the arm with the existing axle and nut. 4. Check shift lever adjustment (see Section 2); then tighten jam nut (A) securely. 5. Install the left-side splash panel. www.mymowerparts.com 9-6 4. Install the instrument pod and secure with the reinstallable rivets. 5. Secure the ignition switch with the retaining ring. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS 10 Torque Specifications (400/500 - Manual Transmission)....................... 10-2 Torque Specifications (400/500 - Automatic Transmission/650 H1) ...... 10-3 Torque Specifications (700 EFI) ............................ 10-5 Tightening Torque (General Bolts) ........................ 10-7 Torque Conversions .............................................. 10-7 www.mymowerparts.com 10-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Specifications (400/500 - Manual Transmission) DRIVE TRAIN COMPONENTS Part BRAKE COMPONENTS Torque Part Bolted To kg-m Engine (Lower Rear/Front) Frame 5.5 Front Differential* Frame/Differential 6.2 Bracket Pinion Housing Differential Housing Differential Housing Cover*** Drive Bevel Gear Nut*** Part ft-lb 40.0 Part Bolted To Torque kg-m ft-lb Brake Disc* Hub 2.1 15.0 Brake Hose Caliper 2.8 20.0 Brake Hose Master Cylinder 2.8 20.0 2.9-3.5 21.025.0 Brake Hose Auxiliary Brake Cyl- 2.8 inder 20.0 Differential Housing 2.9-3.5 21.025.0 Master Cylinder (Rear) Frame 3.5 25.0 Master Cylinder Cover Master Cylinder 0.1 1.0 Shaft 10.0 45.0 72.0 Auxiliary Brake Pedal Lever Axle 3.5 25.0 Differential Gear Case*** Hub 2.3-3.0 16.522.0 Hydraulic Caliper Knuckle/Axle 2.8 Retainer Assembly 20.0 Lock Collar Differential Housing 17.3 Auxiliary Caliper Knuckle/Axle 2.8 Retainer Assembly 20.0 Hub Nut Shaft/Axle (max) 27.6 200.0 Oil Drain Plug Front Differential/ Rear Drive 0.5 3.5 Oil Fill Plug Front Differential/ Rear Drive 2.2 16.0 Oil Drain Plug Engine 2.2 16.0 Inspection Plug Front Differential/ Rear Drive 0.5 3.5 Wheel Hub 5.5 Oil Fitting (400) Engine 0.8 125.0 Engine 2.8 Footrest Frame (8 mm) Frame (10 mm) 5.5 40.0 Shift Lever* Shift Axle 1.1 8.0 SUSPENSION COMPONENTS (Front) Frame 4.8 35.0 40.0 Ball Joint Cap Screw Knuckle 4.8 35.0 6.0 Shock Absorber Frame 4.8 35.0 20.0 Shock Absorber Upper A-Arm 4.8 35.0 Knuckle A-Arm 4.8 35.0 SUSPENSION COMPONENTS (Rear) Coil* Frame 1.7 12.0 Ground Wire Engine 1.1 8.0 STEERING COMPONENTS Handlebar Block Steering Post 2.8 20.0 Steering Post Bearing Housing Frame 2.8 20.0 Steering Post Bearing Flange Frame 2.8 20.0 Lower Steering Bearing Washer Cap Screw*** Steering Post 5.5 40.0 Tie Rod End Knuckle/Steering Post 4.2 30.0 10-2 20.0 Footrest ELECTRICAL COMPONENTS www.mymowerparts.com 2.8 A-Arm EXHAUST COMPONENTS Exhaust Pipe CHASSIS COMPONENTS Axle Retainer Assembly Axle Housing 5.5 40.0 Shock Absorber (Upper) Frame 4.8 35.0 Shock Absorber (Lower) Lower A-Arm 2.8 20.0 A-Arm Frame 4.8 35.0 Swing Arm Axle Housing/Case 4.8 35.0 Knuckle A-Arm 35.0 4.8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ENGINE/TRANSMISSION Part Clutch Shoe Part Bolted To Crankshaft Torque kg-m (400/500 - Automatic Transmission/650 H1) ft-lb 13.0 94.0 72.0 Clutch Sleeve Hub Countershaft 10.0 Crankcase Half (6 mm) Crankcase Half 0.9-1.3 6.5-9.5 Crankcase Half (8 mm) Crankcase Half 2-2.4 3.8 Torque Specifications DRIVE TRAIN COMPONENTS 14.517.0 Cylinder Head (Cap Screw) Cylinder Cylinder Head (6 mm Nut) Cylinder 1.1 8.0 Cylinder Head (8 mm Nut) Cylinder 2.5 18.0 Cylinder Head Cover Cylinder Head 1.0 7.0 Left-Side Cover Crankcase Half 0.9-1.3 6.5-9.5 Mechanical Water Pump Impeller Pump Shaft 1.05 Oil Pump Drive Gear Crank Balancer Shaft 8.0 Oil Pump* Crankcase 1.0 7.0 Output Shaft Gear Output Shaft 10.0 72.0 Part Part Bolted To 27.5 7.5 Torque kg-m ft-lb Engine Mounting Through-Bolt (400/500) Frame 5.5 40.0 Engine (650 H1) Engine Cradle 5.5 40.0 Engine Cradle (650 H1/TRV)** Rubber Mount 3.5 25.0 Rubber Mount (650 H1/TRV) Frame Bracket 4.8 35.0 Front Differential* Frame/Differential 6.2 Bracket 45.0 Rear Output Joint Assembly Engine 2.8 20.0 Input Housing Differential Housing 2.9-3.5 21.025.0 58.0 Rear Output Shaft Output Joint 2.8 20.0 Recoil Starter Left-Side Cover 0.8 6.0 Differential Housing Cover*** Differential Housing 2.9-3.5 21.025.0 Reverse Cam Stopper Housing Crankcase 2.3 16.5 Drive Bevel Gear Nut*** Shaft 10.0 Right-Side Cover Crankcase 0.9-1.3 6.5-9.5 Rotor/Flywheel Nut Crankshaft 16.0 116.0 Shift Stop Housing Crankcase 2.3 Cam Sprocket** Camshaft Starter Cup Spark Plug 72.0 Differential Gear Case*** Hub 2.3-3 16.5-22 Lock Collar Differential Housing 17.3 125.0 16.5 Hub Nut Shaft/Axle (max) 27.6 200.0 1.5 11.0 Oil Drain Plug Front Differential/ Rear Drive 0.5 3.5 Crankshaft 3.5 25.0 Oil Fill Plug 16.0 1.7 12.0 Front Differential/ Rear Drive 2.2 Engine Oil Drain Plug Engine 2.2 16.0 Inspection Plug Rear Drive 0.5 3.5 Wheel Hub 5.5 40.0 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 EXHAUST COMPONENTS Exhaust Pipe (400/500) Engine 2.8 20.0 Exhaust Pipe (650 H1) Engine 2.8 20.0 ELECTRICAL COMPONENTS Coil* Frame 1.7 12.0 Ground Wire Engine 1.1 8.0 10 www.mymowerparts.com 10-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 STEERING COMPONENTS Part Part Bolted To ENGINE/TRANSMISSION (400/500 - Automatic Transmission) Torque kg-m ft-lb Handlebar Block Steering Post 2.8 20.0 Steering Post Bearing Housing Frame 2.8 20.0 Steering Post Bearing Flange Frame 2.8 20.0 Lower Steering Bearing Washer Cap Screw*** Steering Post 5.5 40.0 Tie Rod End Knuckle/Steering Post 30.0 4.2 BRAKE COMPONENTS Part Part Bolted To Torque kg-m ft-lb Clutch Shoe Crankshaft 13.0 94.0 Clutch Cover/Housing Assembly Crankcase 1.1 8.0 Crankcase Half (6 mm) Crankcase Half 0.9-1.3 6.5-9.5 Crankcase Half (8 mm) Crankcase Half 2-2.4 14.5-17 Cylinder Head (Cap Screw) Crankcase 3.8 27.5 Cylinder Head (6 mm) Cylinder 1.1 8.0 Cylinder Head (8 mm) Cylinder 2.5 18.0 Cylinder Head Cover Cylinder Head 1.0 7.0 Driven Pulley Nut** Fixed Face 10.4-11.8 75.085.0 20.0 Fixed Driven Clutch Shaft 10.4-11.8 75.085.0 0.1 1.0 Ground Wire Engine 1.1 8.0 Lever Axle 3.5 25.0 Magneto Cover Crankcase 1.1 8.0 Hydraulic Caliper Knuckle 2.8 20.0 7.5 Knuckle 2.8 20.0 Mechanical Water Pump Pump Shaft Impeller 1.05 Auxiliary Caliper Movable Drive Face** Driveshaft 10.4-11.8 75.085.0 Oil Pump Drive Gear Crank Balancer Shaft 5.0 Brake Disc* Hub 2.1 15.0 Brake Hose Caliper 2.8 20.0 Brake Hose Master Cylinder 2.8 20.0 Brake Hose Auxiliary Brake Cali- 2.8 per Master Cylinder Cover Master Cylinder Auxiliary Brake Pedal CHASSIS COMPONENTS Footrest Frame (8 mm) 2.8 20.0 Footrest Frame (10 mm) 5.5 40.0 Shift Lever* Shift Axle 1.1 8.0 SUSPENSION COMPONENTS (Front) A-Arm Frame 4.8 35.0 Ball Joint Cap Screw Knuckle 4.8 35.0 Shock Absorber Frame 4.8 35.0 Shock Absorber Upper A-Arm 4.8 35.0 Knuckle A-Arm 4.8 35.0 SUSPENSION COMPONENTS (Rear) A-Arm Frame 4.8 35.0 Shock Absorber (Upper) Frame 4.8 35.0 Shock Absorber (Lower) Lower A-Arm 2.8 20.0 Knuckle A-Arm 4.8 35.0 SUSPENSION COMPONENTS (Rear) TBX Model Shock Absorber Frame 4.8 35.0 Shock Absorber Tilt Box Frame A-Arm 2.8 20.0 ATV Frame 3.3 24.0 Cargo Box (Plastic) Tilt Box Frame 1.7 12.0 Side Box Frame 2.8 20.0 Side Box Footwell 1.1 8.0 Rear CV Joint** Engine 2.8 20.0 www.mymowerparts.com 10-4 36.0 Output Shaft Gear Output Shaft 10.0 72.0 Recoil Starter Left-Side Cover 0.8 6.0 Rotor/Flywheel Nut Crankshaft 16.0 116.0 Cam Sprocket** Camshaft 1.5 11.0 Starter Cup Crankshaft 3.5 25.0 V-Belt Cover Crankcase 1.1 8.0 Spark Plug Engine 1.7 12.0 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ENGINE/TRANSMISSION (650 H1) Part Part Bolted To Torque Specifications (700 EFI) Torque kg-m ft-lb Clutch Shoe Crankshaft 31.8 230.0 Clutch Cover/Housing Assembly Crankcase 1.1 8.0 Crankcase Half (6 mm) Crankcase Half 0.9-1.3 6.5-9.5 Crankcase Half (8 mm) Crankcase Half 2.8 20.0 Cylinder Head (Cap Screw) Crankcase 5.5 40.0 Cylinder Head (6 mm) Cylinder 1.1 8.0 DRIVE TRAIN COMPONENTS Part Torque Part Bolted To Engine Mounting Through-Bolt Frame kg-m 5.5 ft-lb 40.0 Engine Mount (Rear) Frame 5.5 40.0 Front Differential**** Frame/Differential Bracket 6.2 45.0 45.0 Cylinder Head (8 mm) Cylinder 2.5 18.0 Cylinder Head Cover Cylinder Head 1.1-1.2 8.0-9.0 Rear Drive Gear Case Frame 6.2 Driven Pulley Nut Fixed Face 13.5 97.5 Pinion Housing Differential Housing Fixed Driven** Clutch Shaft 13.5 97.5 2.9-3.5 21.025.0 Ground Wire Engine 1.1 8.0 Differential Housing Cover*** Differential Housing 2.9-3.5 21.025.0 Magneto Cover Crankcase Drive Bevel Gear Nut*** Shaft 11.013.0 1.1 8.0 Mechanical Water Pump Pump Shaft Impeller 1.05 7.5 Movable Drive Face** Driveshaft 10.4-11.8 75-85 Oil Pump Drive Gear Crank Balancer Shaft 8.5 61.5 Output Shaft Gear Output Shaft 8.5 61.5 Outer Magneto Cover Left-Side Cover 0.8 6.0 Recoil Starter Left-Side Cover 0.8 (Certain 650 H1 Models) 6.0 Rotor/Flywheel Nut Crankshaft 14.5 105.0 Cam Sprocket** Camshaft 1.35 9.8 Starter Cup/Spacer Crankshaft 3.8 27.5 V-Belt Cover Crankcase 1.1 8.0 Spark Plug Engine 1.7 12.0 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 79.594.0 Lock Collar Differential Housing Hub Nut Shaft/Axle 17.3 125.0 (max) 27.6 200.0 Oil Drain Plug Front Differential/ Rear Drive 0.5 3.5 Oil Fill Plug Front Differential/ Rear Drive 2.2 16.0 Oil Drain Plug Engine 2.2 16.0 Inspection Plug Front Differential 0.5 3.5 Wheel Hub 5.5 40.0 EXHAUST COMPONENTS Muffler Frame 2.8 20.0 Exhaust Pipe Cylinder Head 1.9 14.0 ELECTRICAL COMPONENTS Coil**** Ground Wire Frame 1.7 12.0 Engine 1.1 8.0 STEERING COMPONENTS Handlebar Block Steering Post 2.8 20.0 Steering Post Bearing Housing Frame 2.8 20.0 Steering Post Bearing Flange Frame 2.8 20.0 Lower Steering Bearing Steering Post Washer Cap Screw*** 5.5 40.0 Tie Rod End 4.2 30.0 Knuckle/Steering Post www.mymowerparts.com 10-5 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 BRAKE COMPONENTS Part Part Bolted To ENGINE/TRANSMISSION Torque kg-m ft-lb Brake Disc**** Hub 2.1 15.0 Brake Hose Caliper 2.8 20.0 Brake Hose Master Cylinder 2.8 20.0 Brake Hose Auxiliary Brake Cylinder 2.8 Master Cylinder Cover Master Cylinder Auxiliary Brake Pedal Hydraulic Caliper Clutch Shoe Crankshaft 15.0 108.0 Clutch Cover/Housing Assembly Crankcase 0.9 6.5 Crankcase Half (6 mm) Crankcase Half 1.0 7.0 Crankcase Half (8mm) Crankcase Half 2.6 19.0 20.0 Cylinder Head (Cap Screw) Crankcase (Step 1) 2.5 (Step 2) 3.7 18.0 27.0 0.1 1.0 Cylinder Head (6 mm) Cylinder 1.0 7.0 Lever Axle 3.5 25.0 Cylinder Head Cover Suspension Knuckle 2.8 20.0 Cylinder Head (Step 1) 1.0 (Step 2) 1.4 Driven Pulley Nut Fixed Face 10.9 79.0 Fixed Driven** Clutch Shaft 10.9 79.0 CHASSIS COMPONENTS Footrest Frame (8 mm) 2.8 20.0 Footrest Frame (10 mm) 5.5 40.0 Shift Lever**** Shift Axle 1.1 8.0 SUSPENSION COMPONENTS (Front) 7.0 10.0 Ground Wire Engine 1.1 8.0 Magneto Cover Crankcase 1.1 8.0 Movable Drive Face** Driveshaft 10.9 79.0 Oil Pump Drive Gear Crank Balancer Shaft 15.0 108.0 A-Arm Frame 4.8 35.0 Ball Joint Cap Screw Knuckle 4.8 35.0 Output Shaft Gear Output Shaft 10.0 72.0 Shock Absorber Frame 4.8 35.0 Recoil Starter Left-Side Cover 0.8 6.0 Shock Absorber Upper A-Arm 4.8 35.0 Rotor/Flywheel Nut Crankshaft 16.0 116.0 35.0 Cam Idler Shaft Cylinder Head 4.1 29.5 Starter Cup Crankshaft 3.8 27.5 V-Belt Cover Crankcase 0.9 6.5 Spark Plug Engine 1.1 8.0 Knuckle A-Arm 4.8 SUSPENSION COMPONENTS (Rear) A-Arm Frame 5.5 40.0 Shock Absorber (Upper) Frame 4.8 35.0 Shock Absorber (Lower) Lower A-Arm 2.8 20.0 Knuckle 4.8 35.0 A-Arm www.mymowerparts.com 10-6 * w/Blue Loctite #242 ** w/Red Loctite #271 *** w/Green Loctite #609 ****w/Blue Loctite #243 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Tightening Torque (General Bolts) Thread Diameter A (mm) Type of Bolt (Conventional or 4 Marked Bolt) (7 Marked Bolt) Tightening Torque kg-m ft-lb 5 0.2-0.4 1.5-3.0 6 0.4-0.7 3.0-5.0 8 1.0-1.6 7.0-11.5 10 2.2-3.5 16.0-25.5 5 0.3-0.6 2.0-4.5 6 0.8-1.2 6.0-8.5 8 1.8-2.8 13.0-20.0 10 4.0-6.0 29.0-43.5 Torque Conversions ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 1 0.1 21 2.9 41 5.7 61 8.4 81 11.2 2 0.3 22 3.0 42 5.8 62 8.6 82 11.3 3 0.4 23 3.2 43 5.8 63 8.7 83 11.5 4 0.6 24 3.3 44 6.1 64 8.9 84 11.6 5 0.7 25 3.5 45 6.2 65 9.0 85 11.8 6 0.8 26 3.6 46 6.4 66 9.1 86 11.9 7 1.0 27 3.7 47 6.5 67 9.3 87 12.0 8 1.1 28 3.9 48 6.6 68 9.4 88 12.2 9 1.2 29 4.0 49 6.8 69 9.5 89 12.3 10 1.4 30 4.2 50 6.9 70 9.7 90 12.5 11 1.5 31 4.3 51 7.1 71 9.8 91 12.6 12 1.7 32 4.4 52 7.2 72 10.0 92 12.8 13 1.8 33 4.6 53 7.3 73 10.1 93 12.9 14 1.9 34 4.7 54 7.5 74 10.2 94 13.0 15 2.1 35 4.8 55 7.6 75 10.4 95 13.1 16 2.2 36 5.0 56 7.7 76 10.5 96 13.3 17 2.4 37 5.1 57 7.9 77 10.7 97 13.4 18 2.5 38 5.3 58 8.0 78 10.8 98 13.6 19 2.6 39 5.4 59 8.2 79 10.9 99 13.7 20 2.8 40 5.5 60 8.3 80 11.1 100 13.8 10 www.mymowerparts.com 10-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 11 - TROUBLESHOOTING TABLE OF CONTENTS Engine ................................................................... 11-2 Drive ...................................................................... 11-5 Fuel System (400/500/650 H1) ............................. 11-6 Fuel System (700 EFI) .......................................... 11-6 Electrical................................................................ 11-7 Steering/Suspension ............................................. 11-9 Brakes ................................................................. 11-10 www.mymowerparts.com 11-1 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine NOTE: A Condition/Remedy marked with an asterisk (*) is for manual transmission models only. Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. 2. 3. 4. 5. 6. 7. Valve clearance out of adjustment Valve guides worn - seated poorly Valves mistimed Piston rings worn excessively Cylinder bore worn Spark plug seating poorly Starter motor cranks too slowly - does not turn 1. 2. 3. 4. 5. 6. 7. Adjust clearance Repair - replace guides Adjust valve timing Replace rings Replace - rebore cylinder Tighten plug See Electrical in this section Problem: Engine will not start or is hard to start (No spark) Condition Remedy 1. 2. 3. 4. 5. 6. Spark plug fouled Spark plug wet Magneto defective CDI unit/ECU defective Ignition coil defective High-tension lead open - shorted 1. 2. 3. 4. 5. 6. Clean - replace plug Clean - dry plug Replace magneto Replace CDI unit/ECU Replace ignition coil Replace high tension lead Problem: Engine will not start or is hard to start (No fuel reaching the carburetor/fuel injector) Condition Remedy 1. 2. 3. 4. 5. Gas tank vent hose obstructed Carburetor float valve defective Fuel hose obstructed Fuel screens obstructed Fuel pump defective Problem: Engine stalls easily Condition 1. 2. 3. 4. 5. Spark plug fouled Magneto defective CDI unit/ECU defective Carburetor jets/fuel injector obstructed Valve clearance out of adjustment Problem: Engine noisy (Excessive valve chatter) Condition 1. 2. 3. 4. 5. Valve clearance too large Valve spring(s) weak - broken Rocker arm - rocker arm shaft worn Camshaft worn Valve tappets worn 1. 2. 3. 4. 5. Clean vent hose Replace valve Clean - replace hose Clean - replace inlet screen - valve screen Replace fuel pump Remedy 1. 2. 3. 4. 5. Clean plug Replace magneto Replace CDI unit/ECU Clean jets/replace fuel injector Adjust clearance Remedy 1. 2. 3. 4. 5. Adjust clearance Replace spring(s) Replace arm - shaft Replace camshaft Replace tappets Problem: Engine noisy (Noise seems to come from piston) Condition Remedy 1. 2. 3. 4. Piston - cylinder worn Combustion chamber carbon buildup Piston pin - piston pin bore worn Piston rings - ring groove(s) worn 1. 2. 3. 4. Replace - service piston - cylinder Clean chamber Replace - service pin - bore Replace rings - piston Problem: Engine noisy (Noise seems to come from timing chain) Condition Remedy 1. Chain stretched 2. Sprockets worn 3. Tension adjuster malfunctioning www.mymowerparts.com 11-2 1. Replace chain 2. Replace sprockets 3. Repair - replace adjuster FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine noisy (Noise seems to come from clutch) Condition * Remedy * 1. 2. 3. 4. 5. Crankshaft splines - bearings worn Countershaft - hub splines worn Clutch plate teeth worn Driven - drive clutch plates distorted - broken Clutch dampers weak 1. 2. 3. 4. 5. Replace crankshaft - bearings Replace countershaft - hub Replace clutch plate(s) Replace clutch plate(s) Replace dampers Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 2. Lower rod-end bearing worn - burned 3. Connecting rod side clearance too large 1. Replace bearing 2. Replace bearing 3. Replace thrust washer(s) Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. 2. 3. 4. 5. Gears worn - rubbing Splines worn Primary gears worn - rubbing Bearings worn Bushing worn 1. 2. 3. 4. 5. Replace gears Replace shaft(s) Replace gears Replace bearings Replace bushing Problem: Engine noisy (Noise seems to come from secondary-transmission/left-side cover) Condition * Remedy * 1. Gears - shaft(s) worn 2. Bearing(s)/bushing(s) damaged 1. Replace gears - shafts 2. Replace bearing(s)/bushing(s) Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. 2. 3. 4. 5. 6. 7. Drive - driven bevel gears damaged - worn Backlash excessive Tooth contact improper Bearing damaged Gears worn - rubbing Splines worn Final driven shaft thrust clearance too large Problem: Clutch slipping Condition * 1. 2. 3. 4. 5. Release roller out of adjustment - loss of free-play Clutch springs weak Clutch shoes worn Pressure disc worn - distorted Clutch plates (driven - drive) distorted Problem: Clutch dragging Condition * 1. Clutch release roller out of adjustment - too much free-play 2. Clutch springs weak 3. Pressure disc - clutch plates distorted 4. Clutch release mechanism worn - damaged Problem: Transmission will not shift Condition * 1. 2. 3. 4. 5. Gearshift cam broken Gearshift forks distorted Gearshift shaft worn Clutch release mechanism worn - damaged Gearshift linkage adjusted improperly 1. 2. 3. 4. 5. 6. 7. Replace gears Adjust backlash Adjust contact Replace bearing Replace gears Replace shaft(s) Replace thrust washer(s) Remedy * 1. 2. 3. 4. 5. Adjust clutch bolts 1 & 2 Replace springs Replace shoes Replace disc Replace plates Remedy * 1. Adjust clutch bolts 1 & 2 2. Replace springs 3. Replace disc - plates 4. Adjust - replace mechanism Remedy * 1. 2. 3. 4. 5. 11 Replace cam Replace forks Replace shaft Adjust - replace mechanism Adjust linkage www.mymowerparts.com 11-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Transmission will not shift back Condition * 1. 2. 3. 4. Reverse shift cam broken Shift shafts rubbing - sticking Gearshift forks distorted - worn Gearshift lever return spring broken - damaged Problem: Transmission jumps out of gear Condition * 1. 2. 3. 4. Shifting gears (driveshaft - countershaft) worn Gearshift forks distorted - worn Cam stopper spring (gearshift cam) weak Gearshift lever stopper pin worn Remedy * 1. 2. 3. 4. Replace cam Replace shafts Replace forks Replace spring Remedy * 1. 2. 3. 4. Replace gears Replace forks Replace spring Replace pin Problem: Secondary-transmission will not shift or shift back Condition * Remedy * 1. 2. 3. 4. 5. 6. Sliding dog broken - worn Gearshift fork broken - worn Shift lever out of adjustment Gearshift cam worn Cam stopper spring weak Gearshift fork shaft worn 1. 2. 3. 4. 5. 6. Replace dog Replace fork Adjust lever Replace cam Replace spring Replace shaft Problem: Engine idles poorly Condition Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Valve clearance out of adjustment Valve seating poor Valve guides defective Rocker arms - arm shaft worn Magneto defective CDI unit/ECU defective Spark plug fouled - gap too wide Ignition coil defective Float out of adjustment Jets obstructed Pilot screw setting improper Fuel injector obstructed Adjust clearance Replace - service seats - valves Replace guides Replace arms - shafts Replace magneto Replace CDI unit/ECU Adjust gap - replace plug Replace ignition coil Adjust float height Clean jets Adjust pilot screw Replace fuel injector Problem: Engine runs poorly at high speed Condition Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. High RPM “cut out” against RPM limiter Valve springs weak Valve timing out of adjustment Cams - rocker arms - tappets worn Spark plug gap too narrow Ignition coil defective Float level too low Air cleaner element obstructed Fuel hose obstructed Fuel pump defective Problem: Exhaust smoke dirty or heavy Condition 1. 2. 3. 4. 5. 6. Oil (in the engine) overfilled - contaminated Piston rings - cylinder worn Valve guides worn Cylinder wall scored - scuffed Valve stems worn Stem seals defective www.mymowerparts.com 11-4 Shift into higher gear - decrease speed Replace springs Adjust timing Replace cams - arms - tappets Adjust gap Replace ignition oil Adjust float height Clean element Clean or replace hose Replace fuel pump Remedy 1. 2. 3. 4. 5. 6. Drain excess oil - replace oil Replace - service rings - cylinder Replace guides Replace - service cylinder Replace valves Replace seals FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine lacks power Condition Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Valve clearance incorrect Valve springs weak Valve timing incorrect Piston ring(s) - cylinder worn Valve seating poor Spark plug fouled Rocker arms - shafts worn Spark plug gap incorrect Carburetor jets/fuel injector obstructed Float level out of adjustment Air cleaner element obstructed Oil (in the engine) overfilled - contaminated Intake manifold leaking air Cam chain worn Adjust clearance Replace springs Re-time valve gear Replace - service rings - cylinder Repair seats Clean - replace plug Replace arms - shafts Adjust gap - replace plug Clean jets - replace injector Adjust float height Clean element Drain excess oil - change oil Tighten - replace manifold Replace cam chain Problem: Engine overheats Condition Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Carbon deposit (piston crown) excessive Oil low Octane low - gasoline poor Oil pump defective Oil circuit obstructed Gasoline level (in float chamber) too low Intake manifold leaking air Coolant level low Fan malfunctioning Fan switch malfunctioning Thermostat stuck - closed Radiator hoses - cap damaged - obstructed Clean piston Add oil Drain - replace gasoline Replace pump Clean circuit Adjust float height Tighten - replace manifold Fill - examine system for leaks Check fan fuse - replace fan Replace fan switch Replace thermostat Clear obstruction - replace hoses Drive Problem: Power not transmitted from engine to wheels Condition 1. Rear axle shaft serration worn - broken Remedy 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9. Secondary drive - driven gear teeth broken Propeller shaft serration worn - broken Coupling damaged Coupling joint serration worn - damaged Front drive - driven bevel gears broken - damaged Front differential gears/pinions broken - damaged Sliding dog/shaft/fork worn - damaged Front drive axle worn - damaged Front drive axle serration worn - damaged 1. 2. 3. 4. 5. 6. 7. 8. 9. Replace gear(s) Replace shaft Replace coupling Replace joint Replace gear(s) Replace gears - pinions Replace gear(s) Replace axle Replace axle 11 www.mymowerparts.com 11-5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel System (400/500/650 H1) Problem: Starting impaired Condition 1. 2. 3. 4. Starter jet obstructed Starter jet passage obstructed Carburetor leaking air Gas contaminated Problem: Idling or low speed impaired Condition 1. 2. 3. 4. 5. Slow jet obstructed - loose Slow jet outlet obstructed Low speed fuel screw setting incorrect Float height incorrect TPS out of adjustment Problem: Medium or high speed impaired Condition 1. 2. 3. 4. 5. 6. High RPM “cut out” against RPM limiter Main jet obstructed Needle jet obstructed Vacuum piston not operating properly Filter obstructed Float height incorrect Problem: Overflow and fuel level fluctuations Condition 1. 2. 3. 4. 5. Float valve worn - damaged Float valve spring broken Float not working properly Float valve dirty Float height too high - too low Remedy 1. 2. 3. 4. Clean jet Clean passage Replace gasket Drain gas tank and fill with clean gas Remedy 1. 2. 3. 4. 5. Clean - tighten jet Clean outlet Adjust screw Adjust float height Adjust TPS Remedy 1. 2. 3. 4. 5. 6. Shift into higher gear - decrease RPM speed Clean main jet Clean needle jet Check piston operation Clean filter Adjust float height Remedy 1. 2. 3. 4. 5. Replace valve Replace spring Adjust float height - replace float Clean valve Adjust float height Fuel System (700 EFI) Problem: Starting impaired Condition 1. Gas contaminated Problem: Idling or low speed impaired Condition 1. TPS out of adjustment Problem: Medium or high speed impaired Condition 1. High RPM “cut out” against RPM limiter www.mymowerparts.com 11-6 Remedy 1. Drain gas tank and fill with clean gas Remedy 1. Adjust TPS Remedy 1. Decrease RPM speed FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical Problem: Spark absent or weak Condition 1. 2. 3. 4. 5. Ignition coil defective Spark plug defective Magneto defective CDI unit/ECU defective Pick-up coil defective Problem: Spark plug fouled with carbon Condition 1. 2. 3. 4. 5. 6. 7. Mixture too rich Idling RPM too high Gasoline incorrect Air cleaner element dirty Spark plug incorrect (too cold) Valve seals cracked - missing Oil rings worn - broken Problem: Spark plug electrodes overheat or burn Condition 1. 2. 3. 4. Spark plug incorrect (too hot) Engine overheats Spark plug loose Mixture too lean Problem: Magneto does not charge Condition 1. Lead wires/connections shorted - loose - open 2. Magneto coils shorted - grounded - open 3. Regulator/rectifier defective Remedy 1. 2. 3. 4. 5. Replace ignition coil Replace plug Replace magneto Replace CDI unit/ECU Replace pick-up coil Remedy 1. 2. 3. 4. 5. 6. 7. Adjust carburetor Adjust carburetor Change to correct gasoline Clean element Replace plug Replace seals Replace rings Remedy 1. 2. 3. 4. Replace plug Service cooling system Tighten plug Adjust carburetor Remedy 1. Repair - replace - tighten lead wires 2. Replace magneto coils 3. Replace regulator/rectifier Problem: Magneto charges, but charging rate is below the specification Condition Remedy 1. 2. 3. 4. 5. Lead wires shorted - open - loose (at terminals) Stator coils (magneto) grounded - open Regulator/rectifier defective Electrolyte low Cell plates (battery) defective Problem: Magneto overcharges Condition 1. Internal battery short circuited 2. Regulator/rectifier resistor damaged - defective 3. Regulator/rectifier poorly grounded Problem: Charging unstable Condition 1. Lead wire intermittently shorting 2. Magneto internally shorted 3. Regulator/rectifier defective 1. 2. 3. 4. 5. Repair - tighten lead wires Replace stator coils Replace regulator/rectifier Add distilled water Replace battery Remedy 1. Replace battery 2. Replace resistor 3. Clean - tighten ground connection Remedy 1. Replace lead wire 2. Replace magneto 3. Replace regulator/rectifier 11 www.mymowerparts.com 11-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Starter button not effective Condition 1. 2. 3. 4. 5. 6. Battery charge low Switch contacts defective Starter motor brushes not seating Starter relay defective Emergency stop - ignition switch off Wiring connections loose - disconnected Remedy 1. 2. 3. 4. 5. 6. Charge - replace battery Replace switch Repair - replace brushes Replace relay Turn on switches Connect - tighten - repair connections Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates) Condition Remedy 1. 2. 3. 4. 5. Charging rate too low - too high Battery electrolyte insufficient Specific gravity too low Battery run-down - damaged Electrolyte contaminated Problem: Battery discharges too rapidly Condition 1. Electrolyte contaminated 2. Specific gravity too low 3. Charging system not charging 4. Cell plates overcharged - damaged 5. Battery short-circuited 6. Specific gravity too low Problem: Battery polarity reversed Condition 1. Battery incorrectly connected www.mymowerparts.com 11-8 1. 2. 3. 4. 5. Replace battery Keep electrolyte to prescribed level Charge battery - add distilled water Replace battery Replace battery Remedy 1. Replace battery 2. Charge battery - add distilled water 3. Check magneto - regulator/rectifier - circuit connections 4. Replace battery - correct charging system 5. Replace battery 6. Charge battery Remedy 1. Reverse connections - replace battery - repair damage FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Suspension Problem: Handling too heavy or stiff Condition 1. 2. 3. 4. 5. Front wheel alignment incorrect Lubrication inadequate Tire inflation pressure low Tie rod ends seizing Linkage connections seizing Problem: Steering oscillation Condition 1. 2. 3. 4. 5. 6. 7. 8. Tires inflated unequally Wheel(s) wobbly Wheel hub cap screw(s) loose - missing Wheel hub bearing worn - damaged Tie rod ends worn - loose Tires defective - incorrect A-arm bushings damaged Bolts - nuts (frame) loose Problem: Steering pulling to one side Condition 1. 2. 3. 4. 5. Tires inflated unequally Front wheel alignment incorrect Wheel hub bearings worn - broken Frame distorted Shock absorber defective Problem: Tire wear rapid or uneven Condition 1. Wheel hub bearings worn - loose 2. Front wheel alignment incorrect 3. Tire inflation pressure incorrect Problem: Steering noise Condition 1. Caps screws - nuts loose 2. Wheel hub bearings broken - damaged 3. Lubrication inadequate Problem: Suspension too soft Condition 1. Spring(s) weak 2. Shock absorber damaged 3. Shock absorber preload too low Problem: Suspension too stiff Condition 1. A-arm-related bushings worn 2. Shock absorber preload too high Problem: Suspension noisy Condition 1. Cap screws (suspension system) loose 2. A-arm-related bushings worn Remedy 1. 2. 3. 4. 5. Adjust alignment Lubricate appropriate components Adjust pressure Replace tie rod ends Repair - replace connections Remedy 1. 2. 3. 4. 5. 6. 7. 8. Adjust pressure Replace wheel(s) Tighten - replace cap screws Replace bearing Replace - tighten tie rod ends Replace tires Replace bushings Tighten bolts - nuts Remedy 1. 2. 3. 4. 5. Adjust pressure Adjust alignment Replace bearings Repair - replace frame Replace shock absorber Remedy 1. Replace bearings 2. Adjust alignment 3. Adjust pressure Remedy 1. Tighten cap screws - nuts 2. Replace bearings 3. Lubricate appropriate components Remedy 1. Replace spring(s) 2. Replace shock absorber 3. Adjust shock absorber preload Remedy 1. Replace bushing 2. Adjust shock absorber preload 11 Remedy 1. Tighten cap screws 2. Replace bushings www.mymowerparts.com 11-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Rear wheel oscillation Condition 1. 2. 3. 4. 5. 6. 7. 8. 9. Rear wheel hub bearings worn - loose Tires defective - incorrect Wheel rim distorted Wheel hub cap screws loose Axle shaft nut loose (Manual Transmission) Auxiliary brake adjusted incorrectly Rear suspension arm-related bushing worn Rear shock absorber damaged Rear suspension arm nut loose Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9. Replace bearings Replace tires Replace rim Tighten cap screws Tighten nut (Manual Transmission) Adjust brake Replace bushing Replace shock absorber Tighten nut Brakes Problem: Braking poor Condition 1. 2. 3. 4. 5. Pad worn Pedal free-play excessive Brake fluid leaking Hydraulic system spongy Master cylinder/brake cylinder seal worn Problem: Brake lever travel excessive Condition 1. 2. 3. 4. Hydraulic system entrapped air Brake fluid low Brake fluid incorrect Piston seal - cup worn Problem: Brake fluid leaking Condition 1. Connection joints loose 2. Hose cracked 3. Piston seal worn www.mymowerparts.com 11-10 Remedy 1. 2. 3. 4. 5. Replace pads Replace pads Repair - replace hydraulic system component(s) Bleed hydraulic system - correct or repair leaks Replace master cylinder Remedy 1. 2. 3. 4. Bleed hydraulic system Add fluid to proper level Drain system - replace with correct fluid Replace master cylinder Remedy 1. Tighten joint 2. Replace hose 3. Replace brake caliper
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