Arctic_cat_2009_400_TRV_500_550_700_1000_thundercat_service_manual Arctic Cat 2009 400 TRV 500 550 700 1000 Thundercat Service Manual
User Manual: arctic_cat_2009_400_TRV_500_550_700_1000_thundercat_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 2009 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: • • • • • 2009 Y-12 Service Manual 2009 T-14 Service Manual 2009 DVX 300/250 Utility Service Manual 2009 366 Service Manual 2009 700 Mud Pro Service Manual Supplement 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. © 2008 Arctic Cat Inc. www.mymowerparts.com ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 August 2008 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Foreword Click on the blue text to go. Section 1. General Information/Specifications 1 2. Periodic Maintenance 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 www.mymowerparts.com FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS 1 TABLE OF CONTENTS General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-3 Torque Conversions (ft-lb/N-m) ............................... 1-6 Tightening Torque (General Bolts) .......................... 1-6 Break-In Procedure ................................................. 1-6 Gasoline - Oil - Lubricant ........................................ 1-6 Genuine Parts ......................................................... 1-7 Preparation For Storage.......................................... 1-7 Preparation After Storage........................................ 1-8 www.mymowerparts.com 1-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* 400 TRV H1 Models CHASSIS CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 0.35 kg/cm² (5 psi) Tire Inflation Pressure Tire Inflation Pressure MISCELLANY Gas Tank Capacity (rated) 20.8 L (5.5 U.S. gal.) Rear Drive Capacity 250 ml (8.5 fl oz)** Front Differential Capacity 275 ml (9.3 fl oz)*** Engine Oil Capacity 3.3 L (3.5 U.S. qt) - Overhaul 2.8 L (3.0 U.S. qt) - Change 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.) - TRV/Cruiser 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)*** Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil Capacity Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) 2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change Gasoline (recommended) 87 Octane Regular Unleaded Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Drive Belt Width (minimum) 28.5 mm (1.12 in.) Brake Fluid DOT 4 Differential/Rear Drive Lubricant Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) 500 SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 35.6 mm (1.40 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) 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) H2 Models 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.) MISCELLANY 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 3.4 L (3.5 U.S. qt) - Manual 2.5 L (2.6 U.S. qt) - Automatic Gasoline (recommended) 87 Octane Regular Unleaded Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Engine Oil Capacity 2.8 L (3.0 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (Automatic) (minimum) 38 mm (1.33 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) 20.8 L (5.5 U.S. gal.) - Cruiser Coolant Capacity 3.3 L (3.5 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Front Differential/Rear Drive SAE Approved 80W-90 Hypoid Lubricant Drive Belt Width (minimum) 35.6 mm (1.40 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. www.mymowerparts.com 1-2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Specifications EXHAUST COMPONENTS Part Part Bolted To Exhaust Pipe Engine Spark Arrester Muffler DRIVE TRAIN COMPONENTS (400 TRV) Torque ft-lb N-m 20 Part Part Bolted To Torque ft-lb N-m Engine Mounting Through-Bolt Frame 38 52 Front Differential Frame/Differential Bracket 38 52 Output Flange Rear Flange Output Joint 20 27 Pinion Housing Differential Housing 23 31 Differential Housing 23 31 27 48 in.-lb 5.5 Engine/Harness Ground Cap Crankcase Screw 8 11 Coil (500)* Frame 12 16 Coil (EFI Models) Air Filter Housing 7 10 Differential Housing Cover*** 20 27 Drive Bevel Gear Nut** Shaft 59 80 Driven Bevel Gear Nut** Driven Shaft 59 80 Lock Collar Differential Housing 125 169 ELECTRICAL COMPONENTS STEERING COMPONENTS Steering Post Bearing Housing Frame Steering Post Bearing Flange Frame 20 27 Lower Steering Bearing Washer Cap Screw*** Steering Post 40 54 Hub Nut Shaft/Axle (max) 200 272 Tie Rod End Knuckle/Steering Post 30 41 Oil Drain Plug Front Differential/ Rear Drive 45 in.-lb 5 Oil Fill Plug Front Differential/ Rear Drive 16 22 Oil Drain Plug Engine 20 27 23 31 BRAKE COMPONENTS Brake Disc* Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Brake Hose Auxiliary Brake Cylinder 20 27 Rear Drive Input Shaft/Housing Differential Housing Master Cylinder (Rear) Frame 12 16 Wheel Hub 40 54 Hydraulic Caliper Knuckle 20 27 Rear Drive Gear Case Frame 38 52 Master Cylinder Clamp Master Cylinder 6 8 Engine Output Shaft** 27 Brake Pedal Axle 25 34 Rear Gear Case Input Flange 20 Brake Pedal DRIVE TRAIN COMPONENTS (500 - Manual Transmission) CHASSIS COMPONENTS Footrest Frame (8 mm) 20 27 Engine (Lower Rear/Front) Frame 40 54 Footrest Frame (10 mm) 40 54 Front Differential Frame/Differential Bracket 38 52 A-Arm (400/500/H1 Models) Frame 35 47 Pinion Housing 23 31 A-Arm (H2 Models) Frame 50 68 Differential Housing Knuckle Ball Joint 35 47 Differential Housing Cover*** Differential Housing 23 31 Shock Absorber Frame 35 47 Drive Bevel Gear Nut*** Shaft 72 98 Shock Absorber Upper A-Arm 35 47 Lock Collar 169 A-Arm 35 47 Differential Housing 125 Knuckle SUSPENSION COMPONENTS (Front) SUSPENSION COMPONENTS (Rear) Shock Absorber (Upper) Hub Nut Shaft/Axle (max) 200 272 Oil Drain Plug Front Differential/ Rear Drive 45 in.-lb 5 Front Differential/ Rear Drive 16 22 Frame 35 47 Shock Absorber (Upper) (H2 Frame Models) 50 68 Oil Fill Plug Shock Absorber (Lower) Lower A-Arm 20 27 Oil Drain Plug Engine A-Arm Frame 35 47 Inspection Plug A-Arm (H2 Models) Frame 50 68 Front Differential/ Rear Drive Knuckle A-Arm 35 47 Wheel Hub 68 Rear Drive Input Shaft/Housing Differential Housing Rear Drive Gear Case Engine Output Shaft** Knuckle (H2 Models) A-Arm www.mymowerparts.com 50 16 22 48 in.-lb 5.5 40 54 23 31 Frame 45 61 Rear Gear Case Input Flange 20 27 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 1-3 1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DRIVE TRAIN COMPONENTS (500 - Automatic Transmission/H1 Models) Part Part Bolted To ENGINE/TRANSMISSION (400 TRV) Torque Part Part Bolted To Torque ft-lb N-m ft-lb N-m Engine Mounting Through-Bolt Frame 40 54 Clutch Shoe** Crankshaft 147 199 Engine (TRV) Engine Cradle 40 54 Crankcase 8 11 Engine Cradle (TRV)** Rubber Mount 25 34 Clutch Cover/Housing Assembly Rubber Mount (TRV) Frame Bracket 35 47 Left-Side Cover Crankcase 8 11 Front Differential* Frame/Differential Bracket 38 52 Crankcase Half (6 mm) Crankcase Half 10 13.5 Crankcase Half (8 mm) Crankcase Half 21 28 Rear Flange Output Joint 20 Cylinder Nut Crankcase Half 8 11 28 38 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 Output Flange 27 Cylinder Head (Cap Screw) Crankcase Drive Bevel Gear Nut*** Shaft 72 98 Differential Gear Case*** Hub 19 26 Lock Collar Differential Housing 125 169 Hub Nut Shaft/Axle (max) 200 272 Oil Drain Plug Front Differential/ Rear Drive 45 in.-lb 5 Cylinder Head (6 mm) Cylinder 8 11 Cylinder Head (8 mm) Cylinder 20 27 Cylinder Head Cover Cylinder Head 8 11 Oil Pump Drive Gear** Crankshaft 63 86 Driven Pulley Nut** Driveshaft 147 199 Ground Cable Engine 8 11 Output Shaft Flange Nut Output Shaft 59 80 Magneto Rotor Nut Crankshaft 107 146 Oil Fill Plug Front Differential/ Rear Drive 16 22 Cam Sprocket** Camshaft 11 15 Oil Drain Plug Engine 16 22 Starter Motor Crankcase 8 11 Rear Drive Input Shaft/ Housing Differential Housing 23 31 V-Belt Cover Crankcase 8 11 Wheel Hub 40 54 Valve Adjuster Jam Nut Valve Adjuster 7 9.5 Rear Drive Gear Case Frame 38 52 Oil Fitting Engine 8 11 Engine Output Shaft ** Rear Gear Case Input Flange 20 27 Oil Pump* Crankcase 8 11 Movable Drive Face Nut** Clutch Shaft 147 199 Oil Cooler Hose Clamps Engine/Oil Cooler 30 in.-lb 3.4 DRIVE TRAIN COMPONENTS (H2 Models) Engine Mount (Rear) Frame 45 61 Front Differential Frame/Differential Bracket 38 52 Rear Gear Case Frame 38 52 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 Lock Collar Differential Housing 125 169 Hub Nut Shaft/Axle (max) 200 272 Oil Drain Plug Front Differential/ Rear Drive 45 in.-lb 5 Oil Fill Plug Front Differential/ Rear Drive 16 22 Oil Drain Plug Engine 16 22 Wheel Hub 40 54 Rear Drive Input Shaft/ Housing Differentail Housing 23 31 Rear Output Drive Flange Rear Yoke Flange 20 27 Shift Cam Stopper Shift Stopper 8 11 Shift Cam Plate Shift Cam Shaft 8 11 Shifter Housing Crankcase 8 Engine Output Shaft** Rear Gear Case Input Flange 20 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 www.mymowerparts.com 1-4 ENGINE/TRANSMISSION (500 - Manual Transmission) Clutch Shoe Crankshaft 94 127 Clutch Sleeve Hub Countershaft 72 98 Crankcase Half (6 mm) Crankcase Half 8 11 Crankcase Half (8 mm) Crankcase Half 16 22 Cylinder Head (Cap Screw) Cylinder 28 38 Cylinder Head (6 mm Nut) Cylinder 8 11 Cylinder Head (8 mm Nut) Cylinder 18 24 Cylinder Head Cover Cylinder Head 7 9.5 Left-Side Cover Crankcase Half 8 11 Oil Pump Drive Gear** Crank Balancer Shaft 36 49 Oil Strainer Cap Strainer 16 22 Oil Pump* Crankcase 7 9.5 Output Shaft Gear Output Shaft 72 98 Rear Output Shaft Output Joint 20 27 Recoil Starter Left-Side Cover 6 8 Starter Motor Crankcase 8 11 11 Reverse Cam Stopper Housing Crankcase 16 22 27 Right-Side Cover Crankcase 8 11 Magneto Rotor Nut Crankshaft 116 157 Shift Stop Housing Crankcase 16 22 Cam Sprocket** Camshaft 11 15 Starter Cup Crankshaft 25 34 Movable Drive Face Nut** Driveshaft 72 98 Engine Damper Thermostat Housing 7 9.5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ENGINE/TRANSMISSION (500 - Automatic Transmission) Part Part Bolted To ENGINE/TRANSMISSION (H2 Models) Torque Part Part Bolted To Torque ft-lb N-m Clutch Shoe** Crankshaft 94 127 Clutch Shoe** Clutch Cover/Housing Assembly Crankcase 8 11 Clutch Cover/Housing Assembly Crankcase 8 11 Crankcase Half 8 11 Crankcase Half (6 mm) Crankcase Half 8 11 Crankcase Lower Cover (6 mm) Crankcase 8 11 Crankcase Half (8 mm) Crankcase Half 16 22 Crankcase Lower Cover (8 mm) Crankcase 20 27 Cylinder Head (Cap Screw) Crankcase 28 38 Cylinder Head (Cap Screw) Crankcase 40 54 Cylinder Head (6 mm) Cylinder 8 11 Cylinder Head (6 mm) Cylinder 8 11 Cylinder Head (8 mm) Cylinder 18 24 Cylinder Head Cover Cylinder Head 7 9.5 Driven Pulley Nut** Driveshaft 80 110 Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Movable Drive Face Nut** Fixed Drive Face 72 98 Oil Pump Drive Gear** Crank Balancer Shaft 36 49 Crankshaft Crankcase Half ft-lb N-m 221 300 Cylinder Head (8 mm) Cylinder 18 24 Cylinder Head Cover Cylinder Head 8.5 11.5 Driven Pulley Nut** Driveshaft 80 108 Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Oil Filler Cover Crankcase 8 11 Speed Sensor Housing Crankcase 8 11 Crankcase 8 11 Output Shaft Flange Nut Output Shaft 72 98 Starter Motor Recoil Starter Left-Side Cover 6 8 V-Belt Housing Crankcase 8 11 Cylinder 8 11 Magneto Rotor Nut Crankshaft 116 157 Intake Manifold Cam Sprocket** Camshaft 10 13.5 Output Shaft Nut Output Shaft 59 80 Crankshaft 107 145 13.5 Starter Cup Crankshaft 25 34 Rotor/Flywheel Nut Starter Motor Crankcase 8 11 Cam Sprocket** Camshaft 10 11 V-Belt Cover Clutch Cover 8 11 Clutch Shaft 165 224 V-Belt Cover Crankcase 8 Valve Adjuster Jam Nut Valve Adjuster 7 9.5 Movable Drive Face Nut** Oil Pump Crankcase 7 9.5 Oil Pump Cover* Crankcase 8 11 Drive Pulley Nut** Clutch Shaft 80 110 Oil Strainer Cap Crankcase 8 11 Shift Cam Stopper Crankcase 8 11 Shift Cam Stopper Spring Shift Cam Stopper 8 11 Shift Cam Shaft 8 11 ENGINE/TRANSMISSION (H1 Models) Clutch Shoe** Crankshaft 221 300 Shift Cam Plate Clutch Cover/Housing Assembly Crankcase 8 11 Shifter Housing Crankcase 8 11 Crankcase Half (6 mm) Crankcase Half 8 11 Output Yoke Nut Driven Output Shaft 74 100 Crankcase Half (8 mm) Crankcase Half 20 27 Cylinder Head (Cap Screw) Crankcase 40 54 Cylinder Head (6 mm) Cylinder 8 11 Cylinder Head (8 mm) Cylinder 18 24 Cylinder Head Cover Cylinder Head 8.5 11.5 Driven Pulley Nut Driveshaft 80 108 Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Oil Pump Drive Gear** Crank Balancer Shaft 63 85 Output Shaft Nut Output Shaft 59 80 Outer Magneto Cover Left-Side Cover 6 8 Magneto Rotor Nut Crankshaft 107 145 Cam Sprocket** Camshaft 10 13.5 Starter Motor Crankcase 8 11 V-Belt Cover Clutch Cover 8 11 Drive Pulley Nut** Clutch Shaft 165 224 Movable Drive Face Nut** Clutch Shaft 165 224 Output Yoke Nut Driven Output Shaft 74 100 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 www.mymowerparts.com 1-5 1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions (ft-lb/N-m) ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m 1 1.4 26 35.4 51 69.4 76 103.4 2 2.7 27 36.7 52 70.7 77 104.7 3 4.1 28 38.1 53 72.1 78 106.1 4 5.4 29 39.4 54 73.4 79 107.4 5 6.8 30 40.8 55 74.8 80 108.8 6 8.2 31 42.2 56 76.2 81 110.2 7 9.5 32 43.5 57 77.5 82 111.5 8 10.9 33 44.9 58 78.9 83 112.9 9 12.2 34 46.2 59 80.2 84 114.2 10 13.6 35 47.6 60 81.6 85 115.6 11 15 36 49 61 83 86 117 12 16.3 37 50.3 62 84.3 87 118.3 13 17.7 38 51.7 63 85.7 88 119.7 14 19 39 53 64 87 89 121 15 20.4 40 54.4 65 88.4 90 122.4 16 21.8 41 55.8 66 89.8 91 123.8 17 23.1 42 57.1 67 91.1 92 125.1 18 24.5 43 58.5 68 92.5 93 126.5 19 25.8 44 59.8 69 93.8 94 127.8 20 27.2 45 61.2 70 95.2 95 129.2 21 28.6 46 62.6 71 96.6 96 130.6 22 29.9 47 63.9 72 97.9 97 131.9 23 31.3 48 65.3 73 99.3 98 133.3 24 32.6 49 66.6 74 100.6 99 134.6 25 34 50 68 75 102 100 136 Tightening Torque (General Bolts) Type of Bolt Thread Diameter Tightening A (mm) Torque (Conventional or 4 Marked Bolt) (7 Marked Bolt) 5 12-36 in.-lb 6 36-60 in.-lb 8 7-11 ft-lb 10 16-25 ft-lb 5 24-48 in.-lb 6 6-8 ft-lb 8 13-20 ft-lb 10 29-43 ft-lb Break-In Procedure www.mymowerparts.com 1-6 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. 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 ACX All Weather synthetic engine oil, which has been specifically formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 5W-50 oil is acceptable. ATV0049B ! 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. ! WARNING Do not over-fill the gas tank. Tighten the gas tank cap securely after filling the tank. Genuine Parts OILCHARTI RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT 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. FILLING GAS TANK ! 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. 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. When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description. Preparation For Storage ! 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. 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. www.mymowerparts.com 1-7 1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION 1. Clean the ATV thoroughly. If the interior of the air filter housing is dirty, clean the area before starting the engine. 2. Clean the engine. Remove the cloth from the exhaust system. 4. On carbureted models, drain the carburetor float chamber. 3. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 5. Plug the exhaust hole in the exhaust system with a clean cloth. 4. Change the engine/transmission oil and filter. 6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. 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. 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. Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV. www.mymowerparts.com 1-8 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. 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(s). Clean or replace as necessary. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 PERIODIC MAINTENANCE 2 TABLE OF CONTENTS Periodic Maintenance Chart.................................... 2-2 Periodic Maintenance.............................................. 2-3 Lubrication Points.................................................... 2-3 Air Filter................................................................... 2-3 Valve/Tappet Clearance (Feeler Gauge Procedure) ................................... 2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) (400/500/H1 Models) ........................................... 2-5 Valve/Tappet Clearance (Valve Adjuster Procedure) (H2 Models).............. 2-6 Testing Engine Compression .................................. 2-6 Spark Plug(s) .......................................................... 2-7 Muffler/Spark Arrester ............................................. 2-7 Engine/Transmission Oil - Filter - Strainer .............. 2-8 Front Differential/Rear Drive Lubricant .................. 2-10 Adjusting Clutch (500 Manual Transmission) ........ 2-11 Steering Components ........................................... 2-11 Driveshaft/Coupling ............................................... 2-11 Suspension/Shock Absorbers/Bushings ............... 2-11 Nuts/Bolts/Cap Screws.......................................... 2-12 Headlights/Taillight-Brakelight ............................... 2-12 Shift Lever ............................................................. 2-13 Frame/Welds/Racks .............................................. 2-14 Electrical Connections........................................... 2-14 Hydraulic Brake Systems ...................................... 2-14 Burnishing Brake Pads.......................................... 2-15 Checking/Replacing V-Belt (Automatic Transmission)................................... 2-16 www.mymowerparts.com 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 Every Every 3 After Break-In Every Month or Months or (First Mo or 100 Day Every 100 Every 300 Mi) Miles Miles I I = Inspect L = Lubricate R = Replace T = Tighten Every 6 Every Year Months or or Every Every 500 1500 Miles Miles I Fuses C I Air Filter/Drain Tube I Valve/Tappet Clearance I I R C* R I Engine Compression Spark Plug(s) 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) C-L Carburetor Float Chamber (Carbureted Models) Engine Idle RPM (Carbureted Models) As Needed A-R D* I Engine-Transmission Oil Level I A I Engine-Transmission Oil/Filter R Oil Strainer I A R*/R**/R*** R I Front Differential/Rear Drive Lubricant I Clutch (Manual) I Tires/Air Pressure I I Steering Components I I V-Belt (Automatic) I Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) I Nuts/Cap Screws/Screws I C I R (4 Yrs) l A R I R l R I R I T Ignition Timing I Headlight/Taillight-Brakelight I I R Switches I I R Shift Lever I Recoil Starter (500) I Handlebar Grips A-L C-R I R Handlebar I I R Gauges/Indicators I I Frame/Welds/Racks I Electrical Connections I Complete Brake System (Hydraulic & Auxiliary) I Brake Pads I I* R Brake Fluid I I R (2 Yrs) Brake Hoses I I R (4 Yrs) Coolant (Liquid-Cooled Models)/ Cooling System I R l l I C I C L-R R (2 Yrs) * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. www.mymowerparts.com 2-2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Periodic Maintenance Air Filter This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV. Use the following procedure to remove the filter and inspect and/or clean it. 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. CLEANING AND INSPECTING FILTER 1. Remove the seat; then remove the appropriate reinstallable rivets securing the storage compartment. 2 NOTE: Critical torque specifications are located in Section 1. SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Description p/n Compression Tester Kit 0444-213 Oil Filter Wrench 0644-389 Tachometer 0644-275 Timing Light 0644-296 Valve Clearance Adjuster 0444-078 CF260A 2. Raise the storage compartment cover; then slide the cover forward and off the compartment. Remove the storage compartment. NOTE: Special tools are available from the Arctic Cat Service Parts Department. 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. FI467 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) FI468 www.mymowerparts.com 3. Unsnap the four spring-clip fasteners; then remove the air filter cover. 2-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING AND CLEANING DRAINS 1. Inspect the drains beneath the main housing for debris and for proper sealing. CD675A 4. Remove the air filter element/screen assembly and separate the element from the screen. 5. Fill a wash pan larger than the element with a non-flammable cleaning solvent; then dip the element in the solvent and wash it. NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat. KX045A 2. Replace any drain that is cracked or shows any signs of hardening or deterioration. ! CAUTION 6. Dry the element. 7. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element. Attach the element to the filter screen. ! CAUTION A torn air filter element 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. 8. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the carburetor (if equipped). 9. Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter screen down. The drain to the right is the clean air section of the filter housing. Any leak of this 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 drains. Valve/Tappet Clearance (Feeler Gauge Procedure) 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). NOTE: On the H2 models, remove the crankshaft end cap and install the special cap screw (left-hand threads) to rotate the engine. 2. Rotate the crankshaft to the TDC position on the compression stroke (front cylinder on the H2 models). NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. CD674 10. Install the air filter housing cover and secure with the retaining clips. 11. Install the storage compartment; then secure with the reinstallable rivets. www.mymowerparts.com 2-4 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! 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. 0.076-0.127 mm (0.003-0.005 in.) Exhaust 0.152-0.203 mm (0.006-0.008 in.) NOTE: 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. VALVE/TAPPET CLEARANCE (500) Intake 0.05-0.10 mm (0.002-0.004 in.) Exhaust 0.17-0.22 mm (0.007-0.009 in.) 1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). VALVE/TAPPET CLEARANCE (H1/H2 Models) Intake 0.1016 mm (0.004 in.) Exhaust 0.1524 mm (0.006 in.) (Valve Adjuster Procedure) (400/500/H1 Models) To check and adjust valve/tappet clearance, use the following procedure. VALVE/TAPPET CLEARANCE (400) Intake Valve/Tappet Clearance CF005 CC007DC 4. On the H2 models, rotate the engine 270° to the TDC position of the rear cylinder; then repeat step 3. 2. Rotate the crankshaft to the TDC position on the compression stroke. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. NOTE: Use Valve Clearance Adjuster for this procedure. 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. GZ059 5. Install the timing inspection plug; then on the H2 models, remove the cap screw and install the crankcase end cap. 6. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. 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. www.mymowerparts.com 2-5 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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 (Valve Adjuster Procedure) (H2 Models) To check and adjust valve/tappet clearance, use the following procedure. NOTE: The seat, storage compartment cover assembly, compartment box, air filter/filter housing, and left-side/right-side engine 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). NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. NOTE: Use Valve Clearance Adjuster for this procedure. 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. 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. 8. Rotate the engine 270° to the TDC position of the rear cylinder; then repeat steps 4-7 for the rear cylinder. 9. Place the tappet covers with O-rings into position; then tighten the covers securely. 10. Install the spark plugs; then install the timing inspection plug and crankshaft end cap. CF005 2. Rotate the crankshaft to the TDC position on the compression stroke of the front cylinder. Testing Engine Compression To test engine compression, use the following procedure. 1. Remove the high tension lead(s) from the spark plug(s). 2. Using compressed air, blow any debris from around the spark plug(s). ! WARNING Always wear safety glasses when using compressed air. www.mymowerparts.com 2-6 GZ063 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the spark plug(s); then attach the high tension lead(s) to the plug(s) and ground the plug(s) on the cylinder head(s) well away from the spark plug hole(s). 4. Attach the Compression Tester Kit. 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). ATV-0051 ! CAUTION PEAK COMPRESSION MODEL PSI 400 95-115 500 70-85 H1 Models 155-175 H2 Models 75-85 (Front) 120-130 (Rear) 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. 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. 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. ATV0052C 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. 8. If compression is now evident, service the piston rings (see Section 3). Muffler/Spark Arrester Spark Plug(s) At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure. 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. ! 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. www.mymowerparts.com 2-7 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF105A ATV-0075 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. 3. Install the spark arrester assembly with gasket; then secure with the three cap screws. Tighten to 48 in.-lb. 0735-505 3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan. CF104 Engine/Transmission Oil - Filter - Strainer 733-441A OIL - FILTER The engine should always be warm when the oil is changed so the oil will drain easily and completely. 1. Park the ATV on level ground. 2. Remove the oil level stick/filler plug. 4. 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. 5. Using the adjustable Oil Filter Wrench and a suitable wrench, remove the old oil filter. NOTE: Clean up any excess oil after removing the filter. 6. 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. www.mymowerparts.com 2-8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Install the engine drain plug and tighten to 16 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil level stick/filler plug. 400/H1/H2 Models ! 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. 8. Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes. 9. Turn the engine off and wait approximately one minute. ATV-0100AA 13. Inspect the area around the drain plug and oil filter for leaks. STRAINER 2 10. Remove the oil level stick and wipe it with a clean cloth. 1. Remove the belly panel. 11. Install the oil level stick until the threads touch the engine case. 2. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the O-ring (400/500). NOTE: On the 400/H1/H2 models, the oil level stick should be threaded into the case for checking purposes. 12. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. ! 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. CC091D 500 3. Remove the two cap screws securing the strainer; then remove the strainer. NOTE: On the H1/H2 models, thoroughly clean any sealant from the oil strainer cap. ATV-0100 CC163D AT THIS POINT To check/service oil strainer, see Section 3. www.mymowerparts.com 2-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Place the oil strainer into position beneath the crankcase and secure with the cap screws. Tighten securely. 5. Place the strainer cap into position on the strainer making sure the O-ring is properly installed (400/500) or silicone sealant is applied (H1/H2 models); then secure with the cap screws. Tighten securely. AL677C 3. Drain the lubricant into a drain pan by removing in turn the drain plug from each. CC091D 6. Install the belly panel. Front Differential/Rear Drive Lubricant ATV0082A NOTE: On the H2 models, the rear drive incorporates a shock-limiting clutch pack in the gear case input assembly that is designed to cushion driveline shock. ! CAUTION Any lubricant used in place of the recommended gear case lubricant could result in premature failure of the shock limiter. Do not use any lubricant containing graphite or molybdenum additives or other friction-modified lubricants as these may cause severe damage to shock limiter components. When changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, remove the fill plug; the lubricant level should be 1 in. below the threads of the plug. If low, add SAE approved 80W-90 hypoid gear lubricant as necessary. To change the lubricant, use the following procedure. 1. Place the ATV on level ground. 2. Remove each fill plug. 737-651B 4. After all the lubricant has been drained, install the drain plugs and tighten to 45 in.-lb. 5. Pour the appropriate amount of approved SAE 80W-90 hypoid gear lubricant into the filler hole. 6. Install the fill plugs. NOTE: If the differential/rear drive lubricant is contaminated with water, inspect the drain plug, fill 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. www.mymowerparts.com 2-10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjusting Clutch (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. 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. Steering Components 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. AM600D 2. Loosen the jam nuts securing adjustment screw #1 (forward) and adjustment screw #2 (rearward). C. Steering post bearing assembly/bearing housing not broken, worn, or binding. D. Ball joints not worn, cracked, or damaged. 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. CC037D 3. Rotate adjustment screw #1 counterclockwise until it stops. A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn. Suspension/Shock Absorbers/Bushings The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, 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. www.mymowerparts.com B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. 2-11 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 1). CF135A 2. Pull the bulb straight out of the socket; then insert a new bulb. Headlights/TaillightBrakelight 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. HEADLIGHTS NOTE: The bulb portion of a headlight is fragile. HANDLE WITH CARE. When replacing a 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 a bulb when it is hot. Severe burns may result. CF132A 3. Insert the bulb socket assembly into the housing and turn it clockwise to secure. CHECKING/ADJUSTING HEADLIGHT AIM 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). To replace a 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 ATV-0070C To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing. www.mymowerparts.com 2-12 NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. 7. Adjust each headlight by turning the adjuster knob clockwise to raise the beam or counterclockwise to lower the beam. 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. 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. ADJUSTING SHIFT LEVER 1. Remove the seat; then remove the left-side engine cover. CD714A Shift Lever 2. With the ignition switch in the ON position, loosen jam nut (A) (left-hand threads); then loosen jam nut (C) and with the shift lever in the reverse position, adjust the coupler (B) until the transmission is in reverse and the (R) icon appears on the LCD. CHECKING ADJUSTMENT CF258A CF238A 3. Tighten the jam nuts securely; then shift the transmission to each position and verify correct adjustment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place. www.mymowerparts.com 2-13 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 switch 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 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. Hydraulic Brake Systems 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/pedal several times. 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/pedal, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake lever/pedal. Repeat this procedure until no air bubbles are present. 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. On the hand brake if the level in the reservoir is adequate, the sight glass will appear dark. If the level is low, the sight glass will appear clear. On the auxiliary brake the level must be between the MIN and MAX lines on the reservoir. AF637D 738-420A PR377C www.mymowerparts.com 2-14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: During the bleeding procedure, watch the reservoir/sight glass very closely to make sure there is always a sufficient amount of brake fluid. If low, 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. 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. D. Repeat step C until the brake lever/pedal 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. 2 PR237 ! 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. C. Install the new brake pads. D. Secure the caliper to the knuckle and/or axle housing with the cap screws. Tighten to 20 ft-lb. INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, the brake hoses must be replaced. CHECKING/REPLACING 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. PR377B 1. Remove a front wheel. E. Install the wheel. Tighten to 40 ft-lb. 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. 5. Burnish the brake pads (see Burnishing Brake Pads in this section). Burnishing Brake 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 PR376B Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury. NOTE: The brake pads should be replaced as a set. www.mymowerparts.com 2-15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop. 2. Accelerate to 30 mph; then compress brake lever or apply the auxiliary brake to decelerate to 0-5 mph. 3. Repeat procedure on each brake system five times. 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. CC546 Checking/Replacing V-Belt (Automatic Transmission) 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. CC547 4. Remove the V-belt. CC550 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. INSTALLING 1. Spread the faces of the driven clutch by pushing the inner face toward the engine while turning it counterclockwise (500) or threading in a push-bolt (400/H1/H2 models); then when the faces are separated, insert the belt and push down between the faces. 2. Place the V-belt into position over the front shaft. www.mymowerparts.com 2-16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: At this point, the push-bolt can be removed. 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 8 ft-lb. CC550 NOTE: The arrow on the V-belt should point forward. 2 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 (threads coated with red Loctite #271). Tighten the nut to 147 ft-lb (400), 72 ft-lb (500) or 165 ft-lb (H1/H2 models). 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). CC552 www.mymowerparts.com 2-17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION 3 TABLE OF CONTENTS www.mymowerparts.com Engine/Transmission ............................................... 3-2 Specifications (400)................................................. 3-2 Specifications (500)................................................. 3-3 Specifications (H1 Models)...................................... 3-4 Specifications (H2 Models)...................................... 3-4 Troubleshooting ....................................................... 3-5 400 Table of Contents ............................................. 3-9 500 (Automatic Transmission)/H1 Models Table of Contents ............................................... 3-50 500 (Manual Transmission) Table of Contents .... 3-102 H2 Models Table of Contents .............................. 3-166 3-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission Specifications* (400) 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. VALVES AND GUIDES Valve Face Diameter (intake) 30.6 mm (exhaust) 27.0 mm Valve/Tappet Clearance (cold engine) (intake) 0.076-0.127 mm (exhaust) 0.152-0.203 mm Valve Guide/Stem Clearance (max) (intake) 0.04 mm (exhaust) 0.06 mm Valve Guide/Valve Stem Deflection (wobble method) (max) 0.35 mm NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/ transmission. Valve Guide Inside Diameter 5.000-5.015 mm Valve Head Thickness (intake) 2.03 mm (exhaust) 2.28 mm NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. Valve Face/Seat Width (min) (intake) 2.25 mm (exhaust) 2.55 mm NOTE: Critical torque specifications are located in Section 1. Valve Spring Free Length Valve Stem Outside Diameter (intake) 4.975-4.990 mm (exhaust) 4.955-4.970 mm Valve Stem Runout (max) 0.05 mm Valve Seat Angle (intake/exhaust) 45° Valve Face Radial Runout (max) 0.03 mm (min) 42.8 mm (outer) 18.6-21.4 kg Valve Spring Tension @ 32.5 mm (41-47 lb) CAMSHAFT AND CYLINDER HEAD SPECIAL TOOLS Cam Lobe Height (min) A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. (intake/exhaust) 33.53 mm Camshaft Journal/Cylinder Head Clearance(max) 0.081 mm Camshaft Journal Holder Inside Diameter (right & center) 22.01-22.04 mm Camshaft Journal Outside Diameter (right & center) 21.959-21.980 mm (left) 17.51-17.54 mm (left) 17.466-17.480 mm Camshaft Runout Description p/n (max) 0.03 mm Rocker Arm Inside Diameter 12.000-12.018 mm Clutch Sleeve Hub Holder 0444-007 Rocker Arm Shaft Outside Diameter 11.975-11.987 mm Connecting Rod Holder 0444-006 Cylinder Head/Cover Distortion (max) 0.05 mm CYLINDER, PISTON, AND RINGS Crankcase Separator/Crankshaft Remover Driven Pulley Compressor 0444-009 Piston Skirt/Cylinder Clearance 0444-121 Piston Diameter 15 mm from Skirt End 0.060-0.073 mm 80.98-81.00 mm (1st) 8.0 mm Piston Ring Free End Gap (min) Driven Pulley Compressor (2nd) 8.3 mm 0444-140 Bore x Stroke 81.0 x 71.2 mm Magneto Rotor Remover Set 0444-206 Cylinder Trueness (max) 0.01 mm Oil Filter Wrench 0644-389 Piston Ring End Gap - Installed (min) 0.15 mm Piston Ring to Groove Clearance (max) (1st/2nd) 0.06 mm Piston Pin Puller 0644-328 Side Case Puller 0644-262 Side Case Puller 0644-365 Spanner Wrench 0444-153 Surface Plate 0644-016 Valve Clearance Adjuster 0444-078 V Blocks 0644-022 Piston Ring Groove Width (1st) 1.01-1.03 mm (2nd) 1.21-1.23 mm (oil) 2.01-2.03 mm Piston Ring Thickness (1st) 0.97-0.99 mm (2nd) 1.17-1.19 mm Piston Pin Bore (max) 20.008 mm Piston Pin (min) 19.994 mm CRANKSHAFT Connecting Rod (small end) 0.10-0.55 mm Connecting Rod (big end width) 21.95-22.00 mm Connecting Rod (small end deflection) NOTE: Special tools are available from the Arctic Cat Service Parts Department. (max) 20.021 mm Connecting Rod (big end side-to-side) Crankshaft (web-to-web) Crankshaft Runout (max) 0.3 mm 60.8-60.9 mm (max) 0.03 mm * Specifications subject to change without notice. www.mymowerparts.com 3-2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* (500) CLUTCH (Manual Transmission) Clutch Release Screw 1/4-1/2 turn back Drive Plate (fiber) Thickness (min) 2.82 mm Drive Plate (fiber) Tab (min) 2.9 mm Driven Plate (warpage) (max) 0.1 mm Clutch Spring Length (min) 35.6 mm Clutch Wheel Inside Diameter 140.0-140.2 mm (intake) 30.6 mm (exhaust) 27.0 mm Starter Clutch Shoe No groove at any part Clutch Engagement RPM 1700 ± 200 Valve/Tappet Clearance (cold engine) (intake) 0.05-0.10 mm (exhaust) 0.17-0.22 mm Clutch Lock-Up RPM 3700 ± 300 Valve Guide/Stem Clearance (intake) 0.010-0.037 mm (exhaust) 0.030-0.057 mm Primary Reduction Ratio 2.032 (63/31) Secondary Reduction Ratio 1.133 (17/15) VALVES AND GUIDES Valve Face Diameter Valve Guide/Valve Stem Deflection (wobble deflection) (max) 0.35 mm Valve Guide Inside Diameter 5.000-5.012 mm Valve Stem Outside Diameter (intake) 4.975-4.990 mm (exhaust) 4.955-4.970 mm Valve Stem Runout (max) 0.05 mm Valve Head Thickness (min) 0.5 mm Valve Stem End Length (min) 2.3 mm Valve Face/Seat Width 0.9-1.1 mm Valve Seat Angle (intake/exhaust) 45° Valve Face Radial Runout (max) 0.03 mm Valve Spring Free Length (min) 38.8 mm Valve Spring Tension @ 31.5 mm (outer) 18.6-21.4 kg (41-47 lb) CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (intake) 33.13 mm (exhaust) 33.20 mm Camshaft Journal/Cylinder Head Clearance(max) 0.15 mm Camshaft Journal Holder Inside Diameter (right & center) 22.012-22.025 mm (left) 17.512-17.525 mm Camshaft Journal Outside Diameter (right & center) 21.959-21.980 mm (left) 17.466-17.484 mm Camshaft Runout (max) 0.10 mm Rocker Arm Inside Diameter Rocker Arm Shaft Outside Diameter Final Reduction Ratio (front/rear) 3.6 (36/10) Secondary Transmission Reduction Ratio Gear Ratios (low) 2.419 (22/23 x 27/17 x43/27) (high) 1.592 (43/27) (1st) (2nd) (3rd) (4th) (5th) (reverse) Shift 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) 3 0.1-0.3 mm Shift Fork Groove Width (#1 and #2) 5.5-5.6 mm (secondary transmission) 5.5-5.6 mm (reverse) 5.0-5.1 mm Shift Fork Thickness (#1 and #2) 5.3-5.4 mm (secondary transmission) 5.3-5.4 mm (reverse) 4.8-4.9 mm Thermostat Valve Opening Temperature 73.5-76.5°C (164-170°F) Thermostat Valve Lift Over 3 mm @ 90°C (194°F) * Specifications subject to change without notice. 12.000-12.018 mm 11.973-11.984 mm Cylinder Head Distortion (max) 0.05 mm Cylinder Head Cover Distortion (max) 0.05 mm CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance 0.030-0.040 mm Piston Diameter 15 mm from Skirt End 87.465-87.480 mm Piston Ring Free End Gap (min) Bore x Stroke (1st) 9.0 mm (2nd) 9.5 mm 87.5 x 82 mm Cylinder Trueness (max) 0.05 mm Piston Ring End Gap - Installed (min) 0.35 mm Piston Ring to Groove Clearance (max) (1st) 0.180 mm (2nd) 0.150 mm Piston Ring Groove Width (1st) 1.01-1.03 mm (2nd) 1.21-1.23 mm (oil) 2.51-2.53 mm Piston Ring Thickness (1st) 0.97-0.99 mm (2nd) 1.17-1.19 mm Piston Pin Bore (max) 23.03 mm Piston Pin Outside Diameter (min) 22.98 mm CRANKSHAFT Connecting Rod (small end inside diameter)(max) 23.04 mm Connecting Rod (big end side-to-side) Connecting Rod (big end width) Connecting Rod (small end deflection) Crankshaft (web-to-web) Crankshaft Runout 0.10-0.65 mm 24.95-25.00 mm (max) 3 mm 71.02-71.22 mm (max) 0.08 mm www.mymowerparts.com 3-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* Specifications* (H1 Models) (H2 Models) VALVES AND GUIDES VALVES AND GUIDES Valve Face Diameter (intake) 31.6 mm (exhaust) 27.9 mm Valve Face Diameter (intake) 31.6 mm (exhaust) 27.9 mm Valve/Tappet Clearance (cold engine) (intake) 0.1016 mm (exhaust) 0.1524 mm Valve/Tappet Clearance (cold engine) (intake) 0.1016 mm (exhaust) 0.1524 mm Valve Guide/Stem Clearance (intake/exhaust) 0.013 mm Valve Guide/Valve Stem Deflection (wobble method) (max) 0.35 mm Valve Guide Inside Diameter Valve Stem Outside Diameter 5.000-5.012 mm (intake/exhaust) 4.972-4.987 mm Valve Guide/Stem Clearance (intake/exhaust) 0.013 mm Valve Guide/Valve Stem Deflection (wobble method) (max) 0.35 mm Valve Guide Inside Diameter Valve Stem Outside Diameter 5.000-5.012 mm (intake/exhaust) 4.972-4.987 mm Valve Stem Runout (max) 0.1 mm Valve Stem Runout Valve Head Thickness (min) 2.3 mm Valve Head Thickness (min) 2.3 mm Valve Stem End Length (min) 3.97 mm Valve Stem End Length (min) 3.97 mm Valve Face/Seat Width (intake) 2.25 mm (exhaust) 2.60 mm Valve Seat Angle (intake/exhaust) 45° 15’-45° 30’ Valve Face/Seat Width (max) 0.2 mm Valve Face Radial Runout Valve Spring Free Length (min) 38.7 mm Valve Spring Free Length (outer) 19.0 kg (42 lb) (intake/exhaust) 33.53 mm Camshaft Journal/Cylinder Head Clearance (max) 0.04 mm (intake/exhaust) 45° 15’-45° 30’ (max) 0.2 mm (min) 38.7 mm Valve Spring Tension @ 31.5 mm CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (intake) 2.25 mm (exhaust) 2.60 mm Valve Seat Angle Valve Face Radial Runout Valve Spring Tension @ 31.5 mm (max) 0.1 mm (outer) 19.0 kg (42 lb) CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) (intake/exhaust) 33.53 mm Camshaft Journal/Cylinder Head Clearance (max) 0.04 mm Camshaft Journal Holder Inside Diameter (right & center) 21.98-22.04 mm (left) 17.48-17.53 mm Camshaft Journal Holder Inside Diameter (right & center) 21.98-22.04 (left) 17.48-17.53 mm Camshaft Journal Outside Diameter (right & center) 21.96-21.98 mm (left) 17.47-17.48 mm Camshaft Journal Outside Diameter (right & center) 21.96-21.98 (left) 17.47-17.48 mm Camshaft Runout (max) 0.05 mm Camshaft Runout (max) 0.05 mm Rocker Arm Inside Diameter 12.000-12.018 mm Rocker Arm Inside Diameter 12.000-12.018 mm Rocker Arm Shaft Outside Diameter 11.97-11.98 mm Rocker Arm Shaft Outside Diameter 11.97-11.98 mm Cylinder Head/Cover Distortion (max) 0.05 mm Cylinder Head/Cover Distortion CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance 0.045 mm Piston Skirt/Cylinder Clearance Piston Diameter 15 mm from Skirt End (550) 97.948-97.962 mm Piston Diameter 15 mm from Skirt End Piston Diameter 12 mm from Skirt End (700) 101.930101.949 mm Piston Ring End Gap (min) Piston Ring Free End Gap (1st/2nd) 12.5 mm Bore x Stroke 92 x 82 mm - 550 102 x 82 mm - 700 Cylinder Trueness (max) 0.01 mm Piston Ring End Gap - Installed (min) 0.36 mm (1st/2nd) 1.202-1.204 mm (oil) 2.01-2.03 mm Piston Ring Thickness (1st/2nd) 1.970-1.990 mm Piston Pin Bore (min) 22.99 mm CRANKSHAFT Connecting Rod (small end inside diameter) Connecting Rod (big end side-to-side) Connecting Rod (big end width) Connecting Rod @ 150 mm (small end deflection) Crankshaft (web-to-web) Crankshaft Runout (max) 23.021 mm 92 x 71.5 mm (max) 0.0075 mm Piston Ring End Gap - Installed 25 mm (max) 0.3 mm 71 mm 3-4 (1st) 0.034 mm (2nd) 0.033 mm Piston Ring Groove Width (1st/2nd) 1.202-1.204 mm (oil) 2.501-2.503 mm Piston Ring Thickness (1st/2nd) 1.170-1.195 mm Piston Pin Bore (max) 20.012 mm Piston Pin Outside Diameter (min) 19.995 mm CRANKSHAFT Connecting Rod (small end inside diameter) Connecting Rod (big end side-to-side) Connecting Rod @ 150 mm (small end deflection) Crankshaft (web-to-web) (max) 20.021 mm 0.95 mm 21.95 mm (max) 0.3 mm 98 mm Crankshaft Runout (max) 0.03 mm Oil Pump Gerotor Clearance (max) 0.15 mm (max) 0.03 mm * Specifications subject to change without notice. www.mymowerparts.com 0.36 mm Piston Ring to Groove Clearance (max) Connecting Rod (big end width) 0.6 mm 91.949-97.959 mm (1st/2nd) 12.5 mm Cylinder Trueness (max) 23.0 mm Piston Pin Outside Diameter 0.05 mm Bore x Stroke Piston Ring to Groove Clearance (max) (1st/2nd) 0.03 mm Piston Ring Groove Width (max) 0.05 mm CYLINDER, PISTON, AND RINGS * Specifications subject to change without notice. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting NOTE: A Condition/Remedy marked with an asterisk (*) is for the manual transmission model 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 Section 5 - Troubleshooting 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 3 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 1. Replace chain 2. Replace sprockets 3. Repair - replace adjuster 3-5 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. 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. Clutch release roller out of adjustment - too much 1. Adjust clutch bolts 1 & 2 free-play 2. Clutch springs weak 2. Replace springs 3. Pressure disc - clutch plates distorted 3. Replace disc - plates 4. Clutch release mechanism worn - damaged 4. Adjust - replace mechanism 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 www.mymowerparts.com 3-6 Remedy * 1. 2. 3. 4. 5. Replace cam Replace forks Replace shaft Adjust - replace mechanism Adjust linkage 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 3 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 www.mymowerparts.com 3-7 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 www.mymowerparts.com 3-8 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (400) Removing Engine/Transmission.............................. 3-9 Top-Side Components........................................... 3-11 Removing Top-Side Components ......................... 3-11 Servicing Top-Side Components........................... 3-15 Installing Top-Side Components ........................... 3-23 Left-Side Components .......................................... 3-27 Removing Left-Side Components ......................... 3-27 Installing Left-Side Components ........................... 3-29 Right-Side Components ........................................ 3-30 Removing Right-Side Components....................... 3-30 Servicing Right-Side Components ........................ 3-34 Installing Right-Side Components......................... 3-35 Center Crankcase Components............................ 3-38 Separating Crankcase Halves............................... 3-39 Disassembling Crankcase Half ............................. 3-39 Servicing Center Crankcase Components............ 3-41 Assembling Crankcase Half .................................. 3-43 Joining Crankcase Halves..................................... 3-45 Installing Engine/Transmission.............................. 3-46 2. Remove the heat shield; then remove the gas tank (see Section 4). 3. Remove the oil fittings from the engine and account for two O-rings; then disconnect the oil temperature connector and cooling fan connector. KC251 3 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. KC250 AT THIS POINT If the technician’s objective is to service Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame. AT THIS POINT If the technician’s objective is to service/replace left-side cover oil seals 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. KC249 4. Disconnect the speedometer sensor; then remove the E-clip securing the shift rod to the shift arm and disconnect the shift rod. Account for a bushing and flat washer. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 1. Remove the front rack, left and right footwells, and front body panel (see Section 8); then disconnect the negative battery cable from the battery. www.mymowerparts.com 3-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring. KC248 KC170 KC255 5. Remove the inlet air duct, air filter housing, and air silencer duct; then remove the carburetor and set aside leaving the throttle cable attached. KC238 7. Disconnect the gear shift position switch, starter cable, and engine ground cable; then disconnect the trigger coil and stator coil connectors. KC235 KC228A KC236 www.mymowerparts.com 3-10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC228B 8. Remove the front and rear V-belt cooling boots from the V-belt housing. 9. Remove the cap screws from the front and rear output flanges; then remove the front and rear engine mounting through-bolts. KC216 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. NOTE: The engine/transmission does not have to removed from the frame for this procedure. KC242 Removing Top-Side Components A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft KC243 10. Lift the rear of the engine/transmission and swing to the right; then tilt the assembly sufficiently to remove through the right-side frame opening. NOTE: Remove the spark plug, timing inspection plug, and outer magneto cover; then using an appropriate wrench, 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. www.mymowerparts.com 3-11 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1264 NOTE: Keep the mounting hardware with the covers for assembly purposes. MD1245 4. Remove the cam chain tensioner pivot cap screw and washer. 2. Remove the 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. MD1251 5. Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft. CF007A MD1136 MD1354A 3. Loosen the cap screw on the end of the cam chain tensioner; then remove the two cap screws securing the cam chain tensioner assembly. Remove the tensioner assembly and gasket. MD1137 www.mymowerparts.com 3-12 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. CD211 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. 10. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. NOTE: Loop the chain over the cylinder and secure it with a wire to keep it from falling into the crankcase. MD1163 AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. 11. Remove the cam chain guide. MD1132 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 inspect cam chain guide, see Servicing Top-Side Components sub-section. MD1173 www.mymowerparts.com MD1192 3-13 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. MD1213 15. Using Piston Pin Puller, 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 a connecting rod holder. MD1214 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. 14. Using an awl, remove one piston-pin circlip. Take care not to drop it into the crankcase. www.mymowerparts.com 3-14 ! 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the valve cover on the Surface Plate 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 MD1211 A. Starting with the top ring, slide one end of the ring out of the ring-groove. 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. B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT 3 To service piston, see Servicing Top-Side Components sub-section. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. CC130D 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. ! 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 keepers. 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. CC994 www.mymowerparts.com 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. 3-15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CC134D ATV-1004 2. Acceptable width must be at or above specifications. Measuring Valve Face Radial Runout CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. 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 Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator. ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. 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. www.mymowerparts.com 3-16 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. Acceptable inside diameter range must be within specifications. 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. 3. If a valve guide is out of tolerance, the cylinder head 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 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. 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 keepers. 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. CC994 2. Acceptable outside diameter range must be within specifications. www.mymowerparts.com 3-17 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PISTON ASSEMBLY 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 top of the piston. 2. Inspect the piston for cracks in the piston pin, boss, top, and skirt areas. 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. 3. Inspect the piston for seizure marks or scuffing. If piston is scored or galled, replace it with a new one. 4. Inspect the perimeter of each piston for signs of “blowby” indicated by dark discoloration. “Blowby” is caused by worn piston rings, excessive carbon in ring grooves, 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. CC995 Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement exceeds specifications, the piston pin must be replaced. CC400D 2. Remove each ring by working it toward the top 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 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. www.mymowerparts.com 3-18 ATV-1070 2. Inspect and measure the connecting rod small end. If the measurement exceeds specifications, the connecting rod must be replaced (see Center Crankcase Components in this section). 3. Insert an inside dial indicator into the piston-pin bore. Take two measurements to ensure accuracy. The diameter must not exceed specifications. If the diameter exceeds specifications, the piston must be replaced. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1069 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. ATV-1085B 2. Install the compression rings (1 and 2) so the letter(s) 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. 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. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. MD1343A ! 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 ! 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 3-19 3 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. 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. 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 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 3-20 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 #320 grit 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. 3 ATV1013A 2. The lobe heights must not exceed minimum specifications. Inspecting Camshaft Bearing Journal CC390D 4. If any measurement exceeds the limit, bore the cylinder and must be replaced. 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. 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. Loosen the jam nuts and adjuster screws. www.mymowerparts.com 3-21 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 unloader pin for damage. 4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. CF061A 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. 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. CF060A 2. If damaged, the camshaft must be replaced. CC145D 6. If clearance is excessive, measure the journals of the camshaft. www.mymowerparts.com 3-22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Installing Top-Side Components The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and piston pin bore with motor oil; then 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. MD1345 4. Loosely install the two nuts securing 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 a new 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. MD1226A C. Cylinder Head/Camshaft D. Valve Cover/Rocker Arms 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 MD1344 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. Care should be taken that the bottom of the chain guide is secured in the crankcase boss. www.mymowerparts.com 3-23 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1349 MD1270 6. Place a new 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. 8. Install the two lower nuts securing the cylinder head to the cylinder, one in front and one in rear. ! CAUTION Keep tension on the cam chain to avoid damaging the crankcase boss. MD1192 9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to 28 ft-lb. Tighten the two lower cylinder head nuts (from step 8) to 20 ft-lb and the cylinder-to-crankcase nuts (from step 4) to 8 ft-lb. MD1347 10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at top-dead-center. 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 www.mymowerparts.com 3-24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. 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 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. 3 MD1359 14. Place the C-ring into position in its groove in the cylinder head. 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. MD1131 NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder head. 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. CC404D 15. When the camshaft assembly is seated, ensure the following. A. Piston still at top-dead-center. www.mymowerparts.com 3-25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1137 MD1146 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 11 ft-lb; then bend the tab to secure the cap screw. 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 cap screws. MD1137 24. Install the cap screw and spring into the end of the cam chain tensioner. Tighten securely. 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 11 ft-lb. Bend the tab to secure the cap screw. 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards. 21. Remove the cap screw from the end of the chain tensioner. Account for the plunger, spring, and gasket. 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. www.mymowerparts.com 3-26 NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 27. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. Removing Left-Side Components A. Cover/Stator Assembly 1. Remove the cap screws securing the outer magneto cover and remove the cover. 2. Remove the 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. MD1261 28. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 27) to 8 ft-lb. 3 29. Adjust valve/tappet clearance (see Section 2). 30. Place the two tappet covers with O-rings into position; then install and tighten the cap screws securely. MD1186 3. Using Side Case Puller and the 6 mm adapter, remove the left-side cover w/stator assembly. Account for the two alignment pins and the position of the shifter bracket for installing purposes. MD1264 31. Install the spark plug and tighten securely; then install the timing inspection plug. 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. CC946 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. www.mymowerparts.com 3-27 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. 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. MD1368 B. Rotor/Flywheel C. Starter Motor NOTE: Steps 1-3 in the preceding sub-section must precede this procedure. 4. Remove the rotor/flywheel nut. MD1369 MD1194 5. Install the crankshaft protector. MD1370 7. Remove the starter idler gear (No. 1) and starter idler gear (No. 2). MD1365 6. Using Magneto Rotor Remover Set, 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. www.mymowerparts.com 3-28 MD1305 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. 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. 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 cap screws. Install and tighten the three cap screws securely. MD1239 9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 3 11. Remove two starter motor cap screws. MD1122 2. Install the starter motor and tighten the two cap screws securely. 3. Install the shift detent cam making sure the washer is installed. KC217 12. Remove starter motor by tapping lightly with a mallet. NOTE: The starter motor is a non-serviceable component and must be replaced as an assembly. 13. Using an impact screwdriver, remove the three Phillips-head screws holding the crankshaft bearing retainer. Remove the crankshaft bearing retainer. MD1086 4. Install the cam stopper assembly. 5. Install the gear shift shaft assembly and washer making sure to align the alignment marks. MD1122 www.mymowerparts.com 3-29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. MD1239 NOTE: The engine/transmission does not have to be removed from the frame for this procedure. 6. Install starter idler gear (No. 2) and starter idler gear (No. 1). Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the pivot shaft. Account for a flat washer. MD1305 7. Place the key into its notch; then slide the rotor/ flywheel (with the ring gear in place) over the crankshaft. Tighten the nut to 107 ft-lb. C. Cover NOTE: Steps 1-7 in the preceding sub-section must precede this procedure. 8. 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 in a crisscross pattern to 8 ft-lb. 9. Place the outer magneto cover into position on the left-side cover; then install and tighten the four cap screws securely. KC149A 2. Remove the cap screws securing the V-belt cover to the clutch cover; then slide the brake pedal outward and remove the V-belt cover. Account for two alignment pins and a gasket. Right-Side Components AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. KC142A www.mymowerparts.com 3-30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. 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. 5. Remove the V-belt. MD1118 6. Remove the fixed drive face. MD1033 4. Remove the movable drive face and spacer. Account for the movable drive face rollers and outer drive face cover. 3 MD1094 7. Remove the nut holding the driven pulley assembly; then remove the driven pulley assembly. MD1035 MD1068 MD1034 www.mymowerparts.com 8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 3-31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Remove the gear shift position switch. Account for a spacer. MD1092 9. 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. 10. 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. KC326A 13. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes. MD1286 MD1115 D. Gear Shift Position Switch E. Centrifugal Clutch Assembly F. Oil Pump Drive Gear G. Oil Pump Driven Gear 14. 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. NOTE: Steps 1-10 in the preceding sub-section must precede this procedure. 11. Remove the cap screw holding the gear shift position switch onto the right-side crankcase half. MD1014 KC324A www.mymowerparts.com 3-32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1016 15. Remove the cam chain. MD1019 NOTE: Always use a new snap ring when installing the oil pump driven gear. 19. Remove oil pump driven gear. Account for the drive pin and thrust washer. 3 MD1335 16. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT To service clutch components, see Right-Side Components sub-section. Servicing H. Oil Pump/Oil Strainer NOTE: Steps 1-19 in the preceding sub-sections must precede this procedure. MD1018 17. Remove oil pump drive gear. Account for the pin. MD1017 18. Remove the snap ring holding the oil pump driven gear. www.mymowerparts.com 20. Remove three Phillips-head screws holding the oil pump and remove the oil pump. Account for two alignment pins. MD1060 3-33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 21. Remove the four cap screws securing the oil strainer cap; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. ! CAUTION Always replace clutch shoes as a complete set or severe imbalance could occur. 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 MD1207 AT THIS POINT 1. Place the one-way clutch onto the clutch shoe assembly with the green dot or the word “OUTSIDE” directed away from the clutch shoe. To service center crankcase components only, proceed to Separating Crankcase Halves. 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 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. www.mymowerparts.com 3-34 KC330 2. Place the clutch housing onto the clutch shoe/one-way clutch. NOTE: It will be necessary to rotate the clutch housing counterclockwise to properly seat the one-way clutch. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC331A MD1337 3. Check that the clutch shoe can only be rotated counterclockwise in respect to the clutch housing. If the clutch shoe locks up or turns either direction, the one-way clutch must be replaced. 2. Place the strainer cap 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 20 ft-lb. 3 KC332A INSPECTING OIL PUMP 1. Inspect the pump for damage. 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 8 ft-lb. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. NOTE: The oil pump is a non-serviceable component and must be replaced as a complete assembly. DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley assembly is a non-serviceable component and must be replaced as a complete assembly. MD1060 Installing Right-Side Components A. Oil Strainer/Oil Pump 4. Place the thrust washer and drive 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. NOTE: Always use a new snap ring when installing the oil pump driven gear. 1. Place the oil strainer into position beneath the crankcase. Tighten the Phillips-head screws (coated with red Loctite #271) securely. www.mymowerparts.com 3-35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1020 MD1018 7. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread) (coated with red Loctite #271). Tighten to 147 ft-lb. 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. MD1019 5. Install the cam chain. 8. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. 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) to 63 ft-lb. MD1286 9. Install gear shift position switch spacer and switch making sure to align the drive pin with the slot in the shift shaft. MD1017 KC325A www.mymowerparts.com 3-36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC326B MD1342 13. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loctite #271). Tighten to 147 ft-lb. B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. 3 10. Install two alignment pins and place the clutch cover gasket into position. Install the clutch cover. MD1068 MD1115 11. Tighten the clutch cover cap screws to 8 ft-lb. KC134 14. Slide the fixed drive face assembly onto the front shaft. 15. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 in. MD1117 12. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; then install and tighten securely. www.mymowerparts.com 3-37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC137 KC141 NOTE: The arrows on the V-belt should point in direction of engine rotation. NOTE: At this point, the cap screw can be removed from the driven pulley face. 16. Making sure the 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. 18. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. 19. Install two alignment pins and place a new V-belt cover gasket into position on the clutch cover. In a crisscross pattern, tighten cap screws to 8 ft-lb. KC127 17. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft protrude through the cover plate, secure with the nut and tighten to 147 ft-lb. KC142A 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. KC138 www.mymowerparts.com 3-38 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. MD1313 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 driven gear. MD1006 MD1317 MD1012 2. Using Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. 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 washer. 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 3. Remove the driveshaft. www.mymowerparts.com 3-39 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1326 KC325 4. Remove the shift fork shaft and the outer shift fork. 7. Remove the counterbalance gear. Account for the key. 8. Remove the counterbalance shaft. MD1327 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, remove the crankshaft. MD1328 MD1330 6. Noting the position of the slot on the end, remove the shift cam assembly. Account for inner and outer washers. www.mymowerparts.com 3-40 MD1024 ! 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. Servicing Center Crankcase Components NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. 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. NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. SECONDARY GEARS 2. Clean the secondary driven bevel gear teeth of old oil and grease residue. 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. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. Checking Backlash 5. Rotate the secondary driven bevel gear several revolutions in both directions. NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations. 4. Install the secondary driven output shaft assembly. 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 (centered on the gear tooth). 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. ATV-0103 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. ATV-0105 www.mymowerparts.com 3-41 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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 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. 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 CC289D 3. Acceptable gap range must be within specifications. Measuring Connecting Rod (Big End Width) 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. 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. www.mymowerparts.com 3-42 CC290D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 3. Remove the low driven gear washer; then remove the low driven gear. Account for the bushing and bearing. 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 3-4. 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. 4. Remove the washer; then remove the circlip securing the sliding dog. Remove the sliding dog. 5. Remove the high driven gear circlip; then remove the high driven gear. Account for the washer, bushing, and bearing. Assembling 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. NOTE: The countershaft is now completely assembled for installation. Assembling Crankcase Half 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. NOTE: For ease of assembly, install components on the right-side crankcase half. NOTE: If the output shaft was removed, make sure that the proper shim is installed. 1. Install the output shaft into the crankcase making sure the two gears, shim, washer, and nut are in the correct order. www.mymowerparts.com 3-43 3 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 59 ft-lb. 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. CD826A 6. Keeping the slot directed as shown, install the shift cam and inner and outer washers. www.mymowerparts.com 3-44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Install the input driveshaft. KC325 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. MD1326 10. Install the washer, spacer, sleeve, and reverse idler gear. 3 MD1357 MD1032 11. Install the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the driven gear. NOTE: Align the bearing alignment pin on the secondary output shaft. Joining Crankcase Halves MD1198 8. Install the outer shift fork and the shift fork shaft. www.mymowerparts.com 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. MD1327 3-45 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. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws to 10 ft-lb. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. AT THIS POINT 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. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws. After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components. Installing Engine/Transmission 1. From the right side, place the engine/transmission into the frame tilting the top-side forward to clear the frame member. 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. KC216 2. Install the front and rear engine mounting through-bolts and secure with the flange nuts. Tighten to 38 ft-lb. 3. Align the front and rear output flanges with the drive couplers; then secure with the screws and tighten to 20 ft-lb. CC871 5. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws until the halves are correctly joined; then tighten to 21 ft-lb. www.mymowerparts.com 3-46 KC242 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC243 KC228B 4. Install the front and rear V-belt cooling boots and secure with the existing hardware. 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal. Tighten the cap screws evenly to 20 ft-lb and install the muffler retainer springs. 3 KC235 KC237 KC236 5. Connect the stator coil, trigger coil, and gear shift position switch connectors; then attach the engine ground cable and starter cable and secure with cap screws and nuts. Tighten to 8 ft-lb. KC238 KC170 www.mymowerparts.com KC228A 3-47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Place the carburetor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe; then tighten the clamp securely. KC248 KC245A 10. Connect the oil temperature connector and cooling fan connector; then using new O-rings, install the oil fittings onto the crankcase and secure with the cap screws. Tighten to 8 ft-lb. 8. Install the air filter housing onto the frame; then connect the inlet air duct, air silencer duct, and intake housing to carburetor boot and tighten all hose clamps securely. KC249 KC254 9. Install the shift rod onto the shift arm with bushing and flat washer and secure with an E-clip; then connect the speedometer sensor plug. KC250 KC255 KC251 www.mymowerparts.com 3-48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. If the brake pedal was removed during disassembling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. Tighten to 20 ft-lb. KC149A 12. Install the heat shield; then install the gas tank (see Section 4). KC232A 13. Install the front body panel, front rack, and footwells (see Section 8). 14. Pour the appropriate quantity and grade oil into the crankcase; then connect the negative battery cable and move the ATV outside to a well ventilated area. 15. Start the engine and allow the engine to warm up while checking for oil leaks; then shut the engine off and check the oil level. Add oil as required. www.mymowerparts.com 3-49 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (500 - Automatic Transmission/ H1 Models) Removing Engine/Transmission............................ 3-50 Top-Side Components........................................... 3-54 Removing Top-Side Components ......................... 3-54 Servicing Top-Side Components........................... 3-58 Installing Top-Side Components ........................... 3-66 Left-Side Components .......................................... 3-70 Removing Left-Side Components ......................... 3-71 Servicing Left-Side Components .......................... 3-73 Installing Left-Side Components ........................... 3-75 Right-Side Components ........................................ 3-78 Removing Right-Side Components....................... 3-79 Servicing Right-Side Components ........................ 3-82 Installing Right-Side Components......................... 3-86 Center Crankcase Components............................ 3-90 Separating Crankcase Halves............................... 3-90 Disassembling Crankcase Half ............................. 3-90 Servicing Center Crankcase Components............ 3-92 Assembling Crankcase Half .................................. 3-97 Joining Crankcase Halves..................................... 3-98 Installing Engine/Transmission.............................. 3-99 Removing Engine/ Transmission 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. ! 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 side panels. CF242A 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. 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 If the technician’s objective is to service Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame. AT THIS POINT 733-441A If the technician’s objective is to service/replace left-side cover oil seals, front output joint oil seal, rear output joint oil seal, 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. www.mymowerparts.com 3-50 CD799A 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 (500) or gasline hose connector from the fuel rail (H1 models). CD787 CD766C 3 CD786 FI092D 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. 9. Loosen the clamp securing the air intake duct to the air filter housing. 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). www.mymowerparts.com 3-51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Secure the carburetor/throttle body 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. CD805 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. CD774 15. Remove the springs securing the muffler to the exhaust pipe; then remove the muffler. Account for the two exhaust springs. CD796 20. Disconnect the speed sensor connector from the sensor housing. CF138A 16. Remove the two cap screws securing the exhaust pipe to the cylinder head; then remove the pipe. CD794 21. On the right-side, disconnect the gear shift position switch (A), stator connector (B), and the CDI connector (C). CD803 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 3-52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD797A KC201A 22. Disconnect the temperature sensor lead from the wiring harness. 25. Remove the engine mounting through-bolts. Account for all mounting hardware. 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 3-53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD773 CD812A 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 CD813 28. Remove the block from under the engine and lower the engine; then remove the boot clamp from the front output drive yoke. To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. 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. NOTE: The engine/transmission does not have to removed from the frame for this procedure. Removing Top-Side Components A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft 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. CD818 www.mymowerparts.com 3-54 1. Remove the two tappet covers. 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 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 3-55 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 (500). NOTE: On the 500, the cylinder head cap screws are different lengths. CC020D AT THIS POINT www.mymowerparts.com 3-56 To service valves and cylinder head, see Servicing Top-Side Components sub-section. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC025D CC022D C. Cylinder D. Piston 3 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 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. 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. CC032D 14. Using the Piston Pin Puller, 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. CC024D www.mymowerparts.com 3-57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CC033D NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the 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. 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. 2. Place the valve cover on the Surface Plate 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. 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 Servicing Top-Side Components sub-section. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. CC130D ! 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 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. www.mymowerparts.com 3-58 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CC132D 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ATV-1004 2. Acceptable width range must be within specifications. Measuring Valve Face Radial Runout CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. 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 Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator. ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. ATV-1082 2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. www.mymowerparts.com 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. 3-59 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. Acceptable inside diameter range must be within specifications. 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. 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 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. 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. 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. www.mymowerparts.com 3-60 CC132D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PISTON ASSEMBLY ! 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. 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. 3 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 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. 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. 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. 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. www.mymowerparts.com 3-61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. ATV-1069 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. 726-306A 3. On the H1 models, the ring with the orientation mark (MTOP or TOP) should be installed in the second (middle) groove and the ring with the orientation mark (M or O) should be installed in the first (top) groove. CC127D 2. Measure the corresponding piston diameter at the recommended point 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-1024A ATV-1024B ! CAUTION ATV-1085B www.mymowerparts.com 3-62 Incorrect installation of the piston rings will result in engine damage. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CYLINDER/CYLINDER HEAD ASSEMBLY 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. 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. 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 Inspecting 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. CC128D 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. 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. 3. Maximum distortion must not exceed specifications. www.mymowerparts.com 3-63 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting 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. 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. 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. 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 #320 grit 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. 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. 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. www.mymowerparts.com 3-64 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 3 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 3-65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Top-Side Components A. Piston B. Cylinder 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 arrow points toward the exhaust. CC024D 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 NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 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. 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. www.mymowerparts.com 3-66 CC022D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Place a new head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder. 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. CC020D 732-307B NOTE: At this point, oil the camshaft journals, cam lobes, and the three seating surfaces 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. CF057A 8. Install the four cylinder head cap screws (on the 500, note the locations of the different-lengthed cap screws and install with copper washers). Tighten only until snug. 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. 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 28 ft-lb (500) or to 40 ft-lb (H1 models); then tighten the 8 mm nut (from step 9) to 18 ft-lb. Using a crisscross pattern, tighten the 6 mm nuts (from step 9) to 8 ft-lb. Tighten the two cylinder-to-crankcase nuts (from step 4) securely. 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. www.mymowerparts.com 3-67 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. CF013A 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. CD464 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 10 ft-lb. Bend the tab to secure the cap screw. ! 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 10 ft-lb. Bend the tab to secure the cap screw. www.mymowerparts.com 3-68 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD466 20. Place the C-ring into position in its groove in the cylinder head. 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 cap screws. CC012D 21. Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside. ! CAUTION The open end of the plug must be positioned downward. CD469 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. CD468 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. CD470 www.mymowerparts.com 3-69 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD471 CC003D 25. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover. 29. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 28) to 7 ft-lb (500) or 8.5 ft-lb (H1 models). 30. Adjust valve/tappet clearance (see Section 2). 31. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. CC005D 26. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder head and valve cover. CC001D 32. If removed, install the spark plug. Tighten securely. Left-Side Components CC275D 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 cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. www.mymowerparts.com 3-70 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the two cap screws securing the speed sensor housing; then remove the housing. Account for the gasket and two seal washers. Removing Left-Side Components A. Recoil Starter/Outer Magneto Cover B. Water Pump C. Cover D. Rotor/Flywheel NOTE: The H1 models are not 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. 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. 3 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. CD214 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. CD925A 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. 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, remove the side cover. Account for a gasket and two alignment pins. 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. FI085A www.mymowerparts.com 3-71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF075A CD136 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. 10. Using Magneto Rotor Remover Set, remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly and washer. 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. CD939A 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. 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. www.mymowerparts.com 3-72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Left-Side Components A. RECOIL STARTER (500) Disassembling ! WARNING 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. 14. Remove the shift shaft noting the timing marks for assembling purposes. Account for two washers. Always wear safety glasses when servicing the recoil starter. ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. 1. 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. PR430A 15. Remove the gear shift cam plate; then remove the cam stopper and cam stopper spring. Account for two washers. B600D ! CAUTION During the disassembly procedure, make sure all spring tension is released before continuing. 2. Remove the nut. PR434A B601D 3. 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. www.mymowerparts.com 3-73 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Care must be taken when lifting the reel free of the case. Wear safety glasses to avoid injury. 6. 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. If replacement is necessary, follow steps 7-8. B602D 4. Remove the spring, collar, and friction spring; then remove the ratchet and account for the pin. 7. 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. 8. 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. 1. Clean all components. B603D 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. Assembling B604D 5. Carefully lift the reel from the case making sure the spiral spring does not accidentally disengage from the case. 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 www.mymowerparts.com 3-74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B606D B601D 2. Insert the rope through the hole in the reel and tie a knot in the end; then wrap the rope counter- clockwise around the reel leaving approximately 50 cm (20 in.) of rope free of the reel. 9. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch 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. 10. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract. 11. Pull the rope out two or three times to check for correct tension. NOTE: Increasing the rotations in step 10 will increase spring tension. B. STARTER MOTOR AT THIS POINT To service the starter motor, see Section 5. C. WATER PUMP AT THIS POINT To service the water pump, see Section 4. Installing Left-Side Components B605D 6. Install the ratchet making sure the end is properly installed on the reel. 7. Install the friction spring and the spring cover; then install the friction plate with the ratchet guide fitting into the ratchet. 8. While pushing down on the reel, install the nut. Tighten securely. 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. 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. www.mymowerparts.com 3-75 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD950A CD946A 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 www.mymowerparts.com 3-76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD145 PR433A 4. In order on the crankshaft, install a washer, ring gear, key, and the magneto rotor. Secure with the nut. Tighten to 116 ft-lb (500) or 107 ft-lb (H1 models). 3 CD934 CD948A 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. CD940B PR434A 5. Install the thrust washer and shift cam plate onto the shift cam shaft; then coat the cap screw threads with red Loctite #271 and tighten securely. 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. www.mymowerparts.com 3-77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD954A CD925A 11. Tighten the cap screws (from step 9) to 8 ft-lb. 12. Place the speed sensor housing and gasket into position and secure with the two cap screws. Tighten securely. 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. CD069 13. Place the water pump into position and secure with two cap screws. Tighten securely. 14. Install the crossover tube on the water pump and cylinder head making sure the O-ring is properly positioned. 15. Install the shift arm on the shift arm shaft making sure the scribed marks (from removing) are aligned. Tighten securely. PR431A 16. Place the gasket and recoil starter/outer magneto cover into position on the left-side cover; then tighten four cap screws to 6 ft-lb. 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 25 ft-lb. 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 www.mymowerparts.com 3-78 To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 CD966A 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. 3. Remove the V-belt. 4. Remove the nut securing the fixed driven assembly; then remove the assembly. 3 PR388 CD079 2. Remove the nut and washer (500) securing the movable drive face; then remove the face. Account for a spacer. CD963 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. 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. www.mymowerparts.com 3-79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CD973A ! CAUTION Care must be taken when removing the cover so the cover gasket is not damaged. CF085 CD974A NOTE: For steps 8-14, refer to illustration CC829B. CC596 NOTE: Account for and inspect the clutch housing seal. NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. CF088A KEY A. Oil Pump Driven Gear B. Oil Pump Drive Gear C. Clutch Shoe Assembly 10. Remove the two cap screws securing the gear shift position switch; then remove the switch. Account for two neutral contact pins and two springs. D. One-Way Clutch E. Final Drive Carrier Bearing Housing CC829B 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. www.mymowerparts.com 3-80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD997 CD993 11. Remove the nut (left-hand threads) securing the clutch shoe assembly (C). 13. Using an impact wrench, remove the cap screws securing the final drive carrier bearing housing (E); then remove the housing and account for two alignment pins. 3 PR410A 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 www.mymowerparts.com 3-81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD895A 15. Using an impact driver, remove the three Phillips-head screws securing the oil pump; then remove the pump. 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 1. Insert the drive into the clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. CD988 Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. 3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. 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. 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. www.mymowerparts.com 3-82 CC446D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DRIVEN PULLEY ASSEMBLY NOTE: On the H1 models, the driven pulley is a nonserviceable component. If the pulley faces, cam ramps, or sheeve bushing are worn or loose, the pulley must be replaced as an assembly. Do not disassemble the driven pulley on the H1 models. Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Secure Driven Pulley Compressor 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. 3 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 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. NOTE: Do not use the wing nut to compress the spring further. CD050 CD048 3. Install the pilot bushing with the machined end directed down; then fit the bushing into the pulley hub. ! 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. www.mymowerparts.com 3-83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD051 CD054 7. Firmly hold the handle and slowly turn the wing nut counterclockwise to relax the spring. 11. Remove the four pins and spacers from the cam slots in the movable face; then remove the movable face. 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. CF091 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. 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. 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. www.mymowerparts.com 3-84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF092A CD060 3. Inspect two grease seals in the movable face for nicks, cuts, or damage. 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. 3 CF095A 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking. Assembling CF095A 4. Install the movable face sleeve aligning the hole in the spring seat with the spring anchor hole in the movable face. 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. 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. 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. www.mymowerparts.com 3-85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF089A CD052A 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 74 ft-lb 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. Installing Right-Side Components 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. www.mymowerparts.com 3-86 1. Install the gear shift position switch making sure the two neutral contact pins and the two springs are properly positioned. Tighten the Allen-head screws securely. 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 36 ft-lb (500) or 63 ft-lb (H1 models). CD997 CD992 CD994 2. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the Allen-head screws securely. 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. CD999 3. Install the oil pump onto the engine; then tighten the Phillips-head screws securely. CD985A CD988 www.mymowerparts.com 3-87 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF086 CD984 NOTE: When installed correctly, the sides of the drive and driven gears will be flush with each other. 6. Install the clutch shoe assembly and secure with the flange nut (threads coated with red Loctite #271). Tighten to 94 ft-lb (500) or 221 ft-lb (H1 models). 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. PR410A 7. Lightly grease the clutch housing seal; then insert the left fixed drive spacer. PR399A ! CAUTION When installed correctly, the green alignment dot (or the word OUTSIDE) on the one-way clutch is visible. 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 8 ft-lb. 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 www.mymowerparts.com 3-88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD971 PR389 NOTE: The arrows on the V-belt should point forward. 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 and washer (500) (threads coated with red Loctite #271). Tighten the nut to 72 ft-lb (500) or 165 ft-lb (H1 models). ! CAUTION Make sure the splines extend beyond the drive face or a false torque reading and spline damage may occur. CD970 13. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loctite #271). Tighten to 80 ft-lb. FI428A NOTE: At this point, the push-bolt can be removed from between the driven pulley faces. CF262 14. Slide the fixed drive face onto the shaft. 18. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. 15. Spread the faces of the driven pulley by pushing the inner face toward the engine while turning it counterclockwise (500) or thread in a push-bolt (H1 models); then when the faces are separated, insert the belt and push down between the faces. 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 8 ft-lb. 16. Place the V-belt into position on the driven pulley and over the front shaft. www.mymowerparts.com 3-89 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD083 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: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 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. 2. Remove the left-side cap screws securing the crankcase halves. Note the location of the different-lengthed cap screws. 3. Using the Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. KEY A. Secondary Driven Shaft Assembly B. Crank Balancer Assembly C. Crankshaft D. Countershaft Assembly E. F. G. H. Driveshaft Reverse Idler Gear Assembly Gear Shift Shaft Shift Shaft with 2 Forks CC821B 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 3-90 CD267 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the reverse idler gear assembly (F). Account for all washers, shaft, bushing, and the gear. CC675 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. 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. 3 4. Remove the gear shift shaft (G) noting the location of the two holes on the end of the shaft. Account for two washers. CD826 8. Remove the crank balancer. PR380A NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crankshaft. 5. Remove the countershaft assembly (D). Account for a washer on each end of the countershaft. CD832B CC674 NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. 9. Remove the snap ring securing the water pump driven gear shaft. 10. Using a hydraulic press, remove the crankshaft assembly. NOTE: Use a protective end cap to prevent damage to the crankshaft threads. 6. Using a rubber mallet, tap on the crankcase to remove the driveshaft. www.mymowerparts.com 3-91 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the cap O-ring (500). NOTE: Certain models have been built using spiral gears, and certain models have been built using net-forged gears. When performing service procedures on the secondary gears, the technician should use sound judgment in determining which type of gear is being serviced. SECONDARY GEARS (Spiral) 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 PR407 12. Remove the two cap screws securing the oil strainer; then remove the strainer. NOTE: On the H1 models, thoroughly clean any sealant from the oil strainer cap. 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. 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.). PR406 ! CAUTION Unless the secondary drive gear, bevel gear, or bearings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear backlash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. 13. To remove the secondary drive/bevel gear, remove the secondary drive bearing housing; then remove the nut securing the drive/bevel gear shaft in the bearing and using a plastic mallet, drive the shaft out of the bearing. Account for shim/shims. NOTE: Shims should be measured and kept for a starting point in adjusting backlash. 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. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. www.mymowerparts.com 3-92 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Checking Tooth Contact Correcting Tooth Contact NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact. NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart. 2. Clean the secondary driven bevel gear teeth of old oil and grease residue. Tooth Contact Shim Correction 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. Contacts at Top Decrease Shim Thickness Contacts at Root Increase Shim Thickness 4. Install the secondary driven output shaft assembly. 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. 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. ! 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. SECONDARY OUTPUT DRIVE GEARS (Net-Forged) Initial Set-Up ATV-0103 NOTE: If the secondary output driven shaft is replaced or disassembled, the initial set-up must be performed to establish correct gear tooth contact. If only the secondary output drive shaft or secondary output driven gear are replaced, proceed to Correcting Backlash in this sub-section. 1. Install a new bearing (A) onto the secondary driven shaft (B) making sure the bearing locating groove is directed away from the driven gear splines. ATV-0105 MT011A 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft. www.mymowerparts.com ATV-0104 3-93 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MT011B 3. If installing the existing shaft, start with the shims removed during disassembly or if installing a new shaft, start with approximately 1.0 mm shims at point (D); then install the output drive shaft bearing (E) making sure the locating pin is directed toward the center of the shaft. MT008B NOTE: Do not use a new lock nut at this time as this procedure may have to be repeated. 5. Place the assembled shaft into the left crankshaft case; then lightly coat the gear teeth with machinist's lay-out dye. Rotate the shafts through several rotations in both directions. Gear contact should extend from the root to the top of the gear teeth. MT012 MT016A 6. To adjust tooth contact, use the following chart to correctly shim the driven shaft. Tooth Contact Shim Correction Contact at Top Increase Shim Thickness Contact at Root Decrease Shim Thickness 7. After correct tooth contact is established, proceed to Checking Backlash in this sub-section. MT008A 4. Install a new seal (F), output yoke (G), and nut (H) and tighten to 59 ft-lb. Checking Backlash 1. If removed, install the secondary drive/bevel gear shaft into the crankcase; then tighten the nut to 59 ft-lb. 2. Install the secondary drive bearing support; then install the secondary driven output shaft into the crankcase. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear. 4. While rocking the drive bevel gear back and forth, note the maximum backlash reading on the gauge. www.mymowerparts.com 3-94 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MT005A CC290D 5. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). 2. Maximum diameter must not exceed specifications. 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. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. 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 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. After backlash and tooth contact are within specifications, apply red Loctite #271 to the drive shaft threads and driven output shaft threads; then using new nuts, tighten the output shaft nut to 59 ft-lb and the output yoke nut to 74 ft-lb. 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. www.mymowerparts.com 3-95 3 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. 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. Disassembling From the right side: 1. Remove the right drive gear washer; then remove drive gear #2. 2. Remove the reverse driven gear dog; then remove the snap ring. 3. Remove the reverse driven gear spacer; then remove the snap ring. 3. Zero the indicator and rotate the crankshaft slowly. 4. In order, remove washer, reverse driven gear, bearing, and bushing. ! CAUTION 5. In order, remove washer, lock washer, lock washer, and low driven gear. ATV-1074 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 3-4. 6. In order, remove bearing, bushing, and driven gear washer. From the left side: 1. Remove the left drive gear washer; then remove the high driven gear and bearing. 2. In order, remove bushing, driven gear washer, and sliding dog. 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. Assembling From the left side: 1. Install the sliding dog, driven gear washer, and bushing. 2. Install bearing and high driven gear; then install the left drive gear washer. From the right side: 1. Install driven gear washer, bushing, bearing and low driven gear. 2. Install lock washer, lock washer, washer and bushing. ATV-1017 2. Acceptable width range must be within specifications. www.mymowerparts.com 3-96 3. Install bearing, reverse driven gear, washer, and the snap ring. 4. Install reverse driven gear spacer, snap ring, reverse driven gear dog, and drive gear #2; then install the right drive gear washer. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: When installing the countershaft assembly, account for the washer on each end of the shaft. NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool. 3. Install the crank balancer. Assembling Crankcase Half 1. Install the secondary driven output shaft assembly into the crankcase. CD832B 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. CC687 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. 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. CD826A CC688 5. Install the driveshaft. CC689 CC675 www.mymowerparts.com 6. Place a washer on each end of the countershaft assembly; then install the assembly. 3-97 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC674 CD268A 7. 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. 11. Place the oil strainer into position; then secure with the two screws. 8. Insert the two shift forks into the sliding dogs noting the direction of the tabs from disassembling; then install the shift fork shaft. NOTE: Make sure the shift fork tabs face upward and that they are properly seated into the shift cams. 12. Place the oil strainer cap into position making sure the O-ring is in position (500) or silicone sealant is applied (H1 models); then secure the cap with cap screws. Tighten securely. 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. Using a propane torch, heat the right-side crankshaft bearing until the oil begins to smoke; then join the two crankcase halves. CC669 9. Install the reverse idler gear assembly noting the positioning of the two washers, gear, bushing, and shaft. CC695 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. CC668 10. 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. www.mymowerparts.com 3-98 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. 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. 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. 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. 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 16 ft-lb. 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. 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 8 ft-lb. 3 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. CD821 4. Remove the block from beneath the engine; then align the rear drive flanges and secure with four cap screws. Tighten to 20 ft-lb. 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. CD824 5. Install the engine mounting through-bolts and mounting hardware; then tighten to 40 ft-lb. www.mymowerparts.com 3-99 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD809 CD793 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 the nuts securing the exhaust pipe to 20 ft-lb. 8. Secure the engine ground wire to the engine with a cap screw. Tighten to 8 ft-lb. CD810 CD803 9. Connect the gear shift position switch (A), stator connector (B), and the CDI connector (C) to the main wiring harness. CF138A 7. Install the cooling ducts with clamps and tighten the clamps securely. 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. 15. Secure the two coolant hoses to the engine. www.mymowerparts.com 3-100 CD515 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 16. Secure the crankcase vent hose to the air cleaner housing; then secure the inlet boot and carburetor/throttle body to the air filter housing. CD766C CD787 3 FI092C 21. Install the side panels into position. CD785 17. Secure the shift rod to the engine with a new E-clip. 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 and coolant. 24. Install the seat. ! CAUTION CD774 18. Place the left-side footwell and foot peg in position on the frame; then secure with existing hardware. Tighten securely. 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. 19. Install the front body panel with existing hardware. 20. Connect the hose to the fuel pump/fuel rail; then connect the vacuum hose and secure with hose clamps (500) or connect the gasline hose connector to the fuel rail (H1 models). www.mymowerparts.com 3-101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (500 - Manual Transmission) Removing Engine/Transmission.......................... 3-102 Top-Side Components......................................... 3-106 Removing Top-Side Components ....................... 3-106 Servicing Top-Side Components......................... 3-110 Installing Top-Side Components ......................... 3-117 Left-Side Components ........................................ 3-123 Removing Left-Side Components ....................... 3-123 Servicing Left-Side Components ........................ 3-127 Installing Left-Side Components ......................... 3-130 Right-Side Components ...................................... 3-135 Removing Right-Side Components..................... 3-135 Servicing Right-Side Components ...................... 3-139 Installing Right-Side Components....................... 3-142 Center Crankcase Components.......................... 3-146 Separating Crankcase Halves............................. 3-146 Disassembling Crankcase Half ........................... 3-147 Servicing Center Crankcase Components.......... 3-149 Assembling Crankcase Half ................................ 3-159 Joining Crankcase Halves................................... 3-161 Installing Engine/Transmission............................ 3-162 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery 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 the radiator access cover, steering post cover, and storage compartment cover assembly; then remove the storage compartment box. 4. Remove the side panels. CF242A Removing Engine/ Transmission 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. 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 If the technician’s objective is to service Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame. AT THIS POINT ATV-0109 If the technician’s objective is to service/replace left-side cover oil seals, front output joint oil seal, rear output joint oil seal, 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. CD799A www.mymowerparts.com 3-102 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 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 3-103 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD787 AR600D 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 21. Loosen the clamp on the crankcase breather vent hose; then remove the hose. CC334D 18. Disconnect the high tension lead from the spark plug; then remove the coil. 19. Disconnect the battery ground (negative) cable from the crankcase cover; then disconnect the positive cable from the starter motor. CC122D www.mymowerparts.com 3-104 22. Remove the engine/transmission mounting fasteners in the following sequence: FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Lower front: One cap screw, nut, spacer, and washer. CD812A CC123D B. Lower rear: One cap screw, nut, spacer, and washer. 3 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 CD773 3-105 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. 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. CD205 NOTE: The engine/transmission does not have to removed from the frame for this procedure. Removing Top-Side Components A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft CD468 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. 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. CC009D CC001D 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. www.mymowerparts.com 3-106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC010D CC013D 3 CC011D CC266D 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: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. NOTE: Care should be taken not to drop the C-ring down into the crankcase. 6. Remove the cap screw securing the chain tensioner (account for a washer); then remove the tensioner. CC012D 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. 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 3-107 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the cam chain guide. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC017D CC022D C. Cylinder D. Piston NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. CC018D 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 AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. www.mymowerparts.com 3-108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC024D CC032D 14. Using the Piston Pin Puller, 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. 3 CC025D CC033D NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder. ! 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. 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 Servicing Top-Side Components sub-section. AT THIS POINT www.mymowerparts.com To service center crankcase components only, proceed to Removing Left-Side Components. 3-109 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Valves Servicing Top-Side Components NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 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. 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/Rocker Arms NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. CC132D 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. 2. Place the valve cover on the Surface Plate 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. CC134D CC136D CC130D ! 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 3-110 NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator. ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. 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. 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. 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. 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) 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. 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. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator. www.mymowerparts.com 3-111 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. 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. 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 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 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. www.mymowerparts.com 3-112 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. 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. 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. 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 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. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. CC280D www.mymowerparts.com 3-113 3 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 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). 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. CC128D Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. 726-306A ! CAUTION Incorrect installation of the piston rings will result in engine damage. 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. 3. Maximum distortion must not exceed specifications. 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 3-114 CC141D Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CC127D 2. Wash the cylinder in parts-cleaning solvent. ! 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. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit 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 CC390D 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. 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. www.mymowerparts.com 3-115 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. 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 6. If clearance is excessive, measure the journals of the camshaft. www.mymowerparts.com 3-116 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. Installing Top-Side Components 3 A. Piston B. Cylinder 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. CF061A NOTE: With the weight extended, the unloader flat should be even with the camshaft journal. 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. 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 3-117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1024 CC025D 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). 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. NOTE: The chrome (silver) ring should be installed in the top position. ! CAUTION Incorrect installation of the piston rings will result in engine damage. ! CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. 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 arrow points toward the exhaust. CC024D 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. www.mymowerparts.com 3-118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder Head/Camshaft D. Valve Cover/Rocker Arms NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 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. 3 CC022D 7. Place a new head gasket into position on the cylinder. Place the alignment pins into position; then place the cylinder head into position on the cylinder. CC018D CC017D CC020D 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) to 28 ft-lb; then tighten the 8 mm nut (from step 9) to 18 ft-lb. Using a crisscross pattern, tighten the four 6 mm nuts (from step 9) to 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. NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. 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. www.mymowerparts.com 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. 3-119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 732-307B 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 If any of the above factors are not as stated, go back to step 11 and carefully proceed. CC015D 15. Place the tab-washer onto the sprocket making sure it covers the pin in the alignment hole. 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 are in the down position. ATV-1027 ! 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. CF030A 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. www.mymowerparts.com 3-120 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 11 ft-lb. 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 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 11 ft-lb. Bend the tab to secure the cap screw. 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. 19. Place the C-ring into position in its groove in the cylinder. www.mymowerparts.com 3-121 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 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 to the mating surfaces of the cylinder head and valve cover. CD469 CC275D 27. Place the valve cover into position. 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 3-122 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 Removing Left-Side Components A. Recoil Starter B. Hi/Low Shifter Assembly C. Speed Sensor Housing D. Cover CC003D 29. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 28) to 7 ft-lb. 30. Adjust valve/tappet clearance (see Section 2). 31. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the recoil starter. AT THIS POINT To service the recoil starter, see Servicing Left-Side Components sub-section. 3 CC039D CC001D 32. If removed, install the spark plug and tighten securely. 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. 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. 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 snap ring 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. www.mymowerparts.com 3-123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the shift stop housing assembly from beneath the shift shaft housing. Account for the stopper and spring. CC044D 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. CC045D 4. Remove the inside snap ring. CC047D CC046D 5. Remove the two cap screws securing the speed sensor housing; then remove the housing. Account for the gasket. CF037A 8. Using Side Case Puller, 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. CD069 www.mymowerparts.com 3-124 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD134A CD138 10. Remove the idle gear (C), washer, and spacer from the countershaft. 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 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 KEY A. B. C. D. E. Output Shaft with Driven Gear Drive Gears #1 & #2 Idle Gear Shift Fork with Shaft Shift Shaft Assembly F. G. H. I. Starter Gear Assembly Starter Idler Gear Starter Clutch Gear Assembly Rotor/Flywheel CD134B NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 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. 9. Remove the starter gear assembly (F) from the crankcase; then remove the starter idler gear (G) and spacer. CD146 www.mymowerparts.com CD136 3-125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD147 CD149 CD152 CD150 13. Remove the snap ring and washer from the driveshaft; then remove the #1 drive gear (B). Account for a splined bushing and a spacer. 15. Remove the Allen-head screws securing the gear shift position switch; then remove the switch. Account for an O-ring, two contacts, and two springs. CC059D CD159 16. Remove the two cap screws securing the starter to the crankcase; then remove the starter. Account for the wiring forms. CD154A 14. Remove the washer and driven gear (A) from the output shaft; then account for the bushing. www.mymowerparts.com 3-126 CC065D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 17. Remove the nut securing the rotor/flywheel (I) to the crankshaft; then install the magneto rotor remover adapter. CD155 AT THIS POINT CD562 To service center crankcase components only, proceed to Removing Right-Side Components. Servicing Left-Side Components 3 RECOIL STARTER Disassembling ! WARNING CD549 18. Using Magneto Rotor Remover Set, remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly (H) and thrust washer. Always wear safety glasses when servicing the recoil starter. ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. 1. 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. CD550 B600D ! CAUTION During the disassembly procedure, make sure all spring tension is released before continuing. 2. Remove the nut. www.mymowerparts.com 3-127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Carefully lift the reel from the case making sure the spring does not accidentally disengage from the case. B601D 3. 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 Care must be taken when lifting the recoil free of the case. Wear safety glasses to avoid injury. 6. 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. If replacement is necessary, follow steps 7-8. B602D 4. Remove the spring cover, spring, and shaft; then remove the ratchet and account for the pin. 7. 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. 8. 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. 1. Clean all components. B603D 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. B604D www.mymowerparts.com 3-128 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling 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. B601D 9. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch of the reel. 10. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract. 11. Pull the rope out two or three times to check for correct tension. B606D 2. Insert the rope through the hole in the reel and tie a knot in the end; then wrap the rope counter- clockwise around the reel leaving approximately 50 cm (20 in.) of rope free of the reel. NOTE: Increasing the rotations in step 10 will increase spring tension. MEASURING SHIFT FORK (Thickness) 3. Apply low-temperature grease to the spring and hub. NOTE: Whenever a shift fork is out of tolerance, replacement is necessary. 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. 1. Using a calipers, in turn measure the thickness of the machined tip of each shift fork. 5. Align the inner hook of the spiral spring with the notch in the reel. CC296D 2. Shift fork thickness must be within specifications. B605D 6. Install the ratchet onto its spring making sure the end is properly installed on the reel. MEASURING SHIFT FORK GROOVE (Width) 1. Using a calipers, in turn measure the width of each shift fork groove. 7. Install the shaft, spring, and the spring cover; then install the friction plate with the ratchet guide fitting into the ratchet. 8. While pushing down on the reel, install the nut. Tighten securely. www.mymowerparts.com 3-129 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC288D CC065D 2. Shift fork groove width must be within specifications. 2. Place the gear shift position switch 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. MEASURING SHIFT FORK TO GROOVE (Side Clearance) 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. CC049D CC292D 3. Shift fork to groove side clearance must be within specifications. Installing Left-Side Components CC048D 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. www.mymowerparts.com 3-130 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD138 CF038A 4. Place the bushing onto the output shaft; then install the driven gear and washer. 7. In turn on the driveshaft, install the #1 drive gear and washer; then secure with the snap ring. 3 CC063D 5. Install the spacer onto the driveshaft. 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. 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 CC061D 9. Place the idle gear spacer and idle gear onto the countershaft. 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. www.mymowerparts.com 3-131 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 11. With the slot in the shift shaft assembly facing upward, place the assembly on the fixed shaft. CC330D 15. Insert the pin into the starter gear assembly boss in the crankcase; then install starter idler gear #1. CD147 12. Place the left shaft washer on the shift shaft. www.mymowerparts.com 3-132 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 21. Install the 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. 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 116 ft-lb. CF037A 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 25 ft-lb. CD444 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. www.mymowerparts.com 3-133 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC041D CD069 23. In a crisscross pattern, tighten the cap screws (from step 21) to 8 ft-lb. 26. Install the inside snap ring onto the hi/low range shift shaft with the sharp side of the snap ring 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 securely. CC045D 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 snap ring making sure the sharp side of the snap ring faces away from the hi/low-range lever. CC054D 25. Place the speed sensor housing and gasket into position and secure with the two cap screws. Tighten securely. CC044D 28. Place the recoil starter assembly into position on the left-side cover; then tighten four cap screws to 6 ft-lb. www.mymowerparts.com 3-134 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC039D CC027D 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. 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. CF066A 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, 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 www.mymowerparts.com 3-135 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the 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. CD168A C. Primary Drive Clutch Shoe D. Primary Driven Clutch E. Primary Drive Clutch Housing CC034D NOTE: The water pump housing does not have to be removed when removing the right-side cover. 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. www.mymowerparts.com 3-136 CD171 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC074D CC076D 9. Remove the release plate. Account for four springs. 13. Scribe a line across the primary driven clutch assembly to aid in assembling. 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. 3 ! 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 Right-Side Components sub-section. Servicing F. Gear Shift Cam Plate/Guide G. Oil Pump/Oil Strainer CF043 12. Using the Clutch Sleeve Hub Holder to hold the clutch sleeve hub, remove the nut and washer. NOTE: Steps 1-14 in the preceding sub-sections must precede this procedure. 15. Remove the cam chain from the crankcase. www.mymowerparts.com 3-137 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. CC080D CC164D ! 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. 20. Remove the snap ring securing the oil pump driven gear; then remove the gear. Account for the pin and the washer. CF070A 17. Remove the gear shift shaft from the crankcase. CC088D CC085D 18. Release the tension from the gear shift cam stopper arm spring. CC089D 21. Remove the three Phillips-head screws securing the oil pump; then remove the oil pump. www.mymowerparts.com 3-138 CC086D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: It may be necessary to use an impact driver to loosen the screws. Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring/ Assembling) CD190 22. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the O-ring. 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. CC091D 23. Remove the two Phillips-head cap screws securing the strainer. CC239D 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. CC163D AT THIS POINT To service center crankcase components only, proceed to Separating Crankcase Halves. www.mymowerparts.com CC245D 3-139 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Maximum driven plate warpage must not exceed specifications. Measuring Clutch Drive Plate (Fiber) Thickness 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 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 1. Place the clutch hub upside down into the primary gear assembly. 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. 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 CC920 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. Always replace clutch shoes as a complete set or severe imbalance could occur. CF044A ATV1014 www.mymowerparts.com 3-140 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF045A CC239D 3. Install the pressure plate onto the hub making sure the alignment dots are correctly positioned. 6. Place the clutch hub assembly into the primary gear assembly. 3 CF047A 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. 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. CC924 5. Place the primary gear assembly on a clean, flat surface; then install the primary washer into the assembly. CD989A www.mymowerparts.com 3-141 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Right-Side Components 4. Place the pin and washer into position on the oil pump shaft, install the oil pump driven gear, and secure with the snap ring. A. Oil Strainer/Oil Pump B. Gear Shift Shaft 1. Place the oil strainer into position beneath the crankcase and tighten securely with the Phillips-head cap screws. CC088D 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. CC163D 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 16 ft-lb. CF073A 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 7 ft-lb. CC164D 6. Attach the spring to the gear shift cam stopper arm. www.mymowerparts.com 3-142 CC090D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC086D CF070A 3 CF072A 7. Install the gear shift shaft. CD481 9. Place the chain into the crankcase; then secure it from the top side with a wire for ease of assembling. CC085D C. Primary Driven Gear D. Primary Driven Clutch E. Primary Drive Clutch Shoe CC079D 10. Install the primary driven washers 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 tightened to 58 ft-lb. CD198B www.mymowerparts.com 3-143 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! 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. 14. Install the clutch shoe and washer; then secure with the starter clutch shoe nut (left-hand threads). Tighten to 94 ft-lb; then using a center punch, stake the nut. 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 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. CC078D NOTE: Note the alignment mark scribed on the primary driven gear assembly during disassembly. NOTE: Tighten the four roller assembly cap screws in a crisscross pattern making sure there is no clearance between the clutch plates when secured. 12. Using the Clutch Sleeve Hub Holder, install the nut and washer. Tighten to 72 ft-lb. CC074D 16. Install the clutch release arm and release roller guide making sure the release roller and guide are aligned. CD479 13. Place the primary drive one-way clutch into the starter clutch housing noting the word OUTSIDE for proper placement. CD166A 17. Secure the clutch release arm with the cap screw coated with blue Loctite #243. Tighten securely. www.mymowerparts.com 3-144 CF043 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CC073D 18. Install the reverse cam stopper housing and gasket making sure the stopper and spring are correctly positioned. Tighten to 16 ft-lb. CF039A 21. Tighten the cap screws in a crisscross pattern to 8 ft-lb. 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. 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. CD910A CC027D 23. Using the oil filter wrench, install a new oil filter. CF067 NOTE: Care should be taken that the alignment pins are installed in the right-side cover. www.mymowerparts.com 3-145 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the 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. CC067D 24. Install the coolant hose on the water pump and secure with the clamp. CC096D Center Crankcase Components 3. Remove the left-side 8 mm cap screws (two from inside the case) securing the crankcase halves. Note the location of the different-lengthed cap screws. 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 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 CC097D 4. Remove the right-side 8 mm cap screws securing the crankcase halves. 1. Remove the right-side 6 mm cap screws (one from inside the case) securing the crankcase halves. Note the location of the different-lengthed cap screws. CC098D 5. Using the Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins, an O-ring, and a washer. CC530D www.mymowerparts.com 3-146 NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CC099D 3 CD227 KEY A. B. C. D. E. F. Crank Balancer Assembly Crankshaft Balancer Drive Gear with Pin Countershaft Assembly Shift Shaft with Fork Gear Shift Cam G. H. I. J. K. Reverse Shift Cam Shift Shaft with Three Forks Driveshaft Assembly Output Shaft Reverse Idle Gear CC803C 1. Remove the two shift shafts (E and H). 2. Remove the reverse shift cam (G) and spacer. 3. Disengage four forks from the gear shift cam (F); then remove the reverse shifter fork. CF078A CC105D CC102D 4. Remove the gear shift cam (F). www.mymowerparts.com 3-147 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC106D 5. Remove the three remaining forks noting their positions for assembling purposes. CD832 10. Remove the crank balancer assembly (A). 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 snap ring. 7. Simultaneously, remove the driveshaft assembly (I) and countershaft assembly (D). Account for the washer on the countershaft. 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. CD832B NOTE: There is a flat spot on the crank balancer to allow clearance past the crankshaft. 11. Using the Crankcase Separator/Crankshaft Remover, push the crankshaft assembly out of the crankcase. 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. CC115D AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. ! CAUTION CD826 9. Remove the driven gear from the crank balancer assembly (A). Account for a key. www.mymowerparts.com 3-148 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. 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). 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 CC482D 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 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. 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. ATV-0103 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 3-149 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-0105 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. 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 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. 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) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. www.mymowerparts.com 3-150 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. 2. Acceptable width range must be within specifications. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Crankshaft (Runout) DRIVESHAFT Disassembling 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. 1. In order, remove the reverse dog, snap ring, washer, reverse driven gear, and bushing from the driveshaft. ATV-1074 CC228D 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 3-4. Measuring Crankshaft (Web-to-Web) CC227D 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. CC226D ATV-1017 2. Acceptable width range must be within specifications. www.mymowerparts.com CC225D 3-151 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC224D CC221D 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. CC220D CC223D CC508D 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 snap ring. CC219D www.mymowerparts.com 3-152 5. Remove the 3rd driven snap ring; then remove the 3rd driven lock washer (right side) from the driveshaft. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the 3rd driven lock washer (right side) from the driveshaft. Note the tabs facing toward the 5th driven gear for assembling purposes. CC216D 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. CC215D 6. Remove the 3rd driven gear from the driveshaft. CC211D 10. Remove the 5th driven gear from the driveshaft. CC214D 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. CC210D 11. In order, remove the 2nd driven snap ring, washer, gear, and bushing from the driveshaft. CD248 www.mymowerparts.com 3-153 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling 1. In order, install the 2nd driven bushing, gear, washer, and snap ring onto the driveshaft. CC209D CC206D CC208D CC207D CC207D CC208D CC206D AT THIS POINT To service secondary gears, see Servicing Center Crankcase Components in this sub-section. CC209D 2. Install the 5th driven gear onto the driveshaft. www.mymowerparts.com 3-154 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 snap ring onto the driveshaft. 3 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 interlock 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 3-155 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC216D CC221D 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 snap ring. 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. CC219D CC508D 8. Install the 1st driven washer (left side) onto the shoulder of the splined shaft; then install the 1st driven bushing and gear. www.mymowerparts.com 3-156 CC220D CC223D 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. CC842 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! 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 3 CC843 12. In order, install the reverse driven gear, washer, snap ring, 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 CD242 CC226D 2. Remove the 5th drive gear from the countershaft. www.mymowerparts.com 3-157 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC203D CC199D 3. Remove the 5th drive washer and 5th drive snap ring from the countershaft. 6. Remove the other 4th drive washer from the countershaft. Assembling 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 snap ring. CC201D CC199D 3. Install the 3rd drive gear; then install the 5th drive snap ring onto the countershaft. CC200D 4. Remove the 3rd drive gear from the countershaft. 5. Remove the 4th drive snap ring securing the 4th drive gear on the countershaft; then remove the first 4th drive washer and 4th drive gear. Account for the bushing. CC200D 4. Install the 5th drive washer and 5th drive gear onto the countershaft. www.mymowerparts.com 3-158 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC201D CC117D 5. Install the 2nd drive gear and washer onto the countershaft. 3 CC116D CD242 NOTE: The countershaft is now completely assembled for installation. 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. 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. CC688 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 72 ft-lb. CC689 www.mymowerparts.com NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool. 3-159 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 6. Simultaneously, install the driveshaft and countershaft assemblies making sure the washer is on the countershaft. CD232A CD832A 7. Install the reverse idle shaft with snap ring making sure the oil hole in the shaft is facing downward; then install a washer, bushing, reverse idle gear, and a washer. 4. With the key in position, slide the driven gear onto the crank balancer making sure the timing marks are aligned. CF055 CD826 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. 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. CD268A www.mymowerparts.com 3-160 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC107D CC104D NOTE: Prior to joining crankcase halves, turn the shift cam to ensure all gears shift properly. Joining Crankcase Halves CC106D 9. Engage the four forks to the gear shift cam; then install the reverse shift cam and spacer. 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. CC234DA CC105D 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. CC103D 10. Install the two gear shift shafts; then verify that the two crankcase half alignment pins are in place. www.mymowerparts.com 3-161 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC098D CC095D 4. From the right side, install the 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 16 ft-lb. 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 8 ft-lb. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. ! CAUTION After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components. CC097D 5. From the left side, install the case half 6 mm cap screws noting the location of the wiring form; then tighten only until snug. Installing Engine/Transmission NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 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. CC096D 6. From the right side, install the 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 3-162 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 under it; then install the propeller shaft and output flange into the rear drive coupler. 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. 3 CD821 4. Remove the block from beneath the engine; then align the rear drive flanges and secure with four cap screws. Tighten to 20 ft-lb. CC124D 8. Connect the positive cable to the starter motor and install the protective boot. 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. Tighten to 40 ft-lb. AR604D 9. Connect the battery ground (negative) cable to the crankcase cover. www.mymowerparts.com 3-163 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AR600D CD787 10. Install the coil and secure with two cap screws; then install the high tension lead on the spark plug. 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 CC121D CD786 12. Install the air filter housing; then connect the crankcase breather and the inlet air duct. Secure with the clamps. www.mymowerparts.com 3-164 14. Connect the speed sensor connector to the sensor housing. CD794 CD785 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 the exhaust pipe cap screws to 20 ft-lb. 19. Connect the temperature sensor wire to the main harness. CD788 CF138A 20. Connect the gear shift position switch (A), stator connector (B), and the CDI connector (C) to the main harness. 3 CD803 16. Swing the shift rod back into position on the engine shift arm; then secure with the E-clip. 17. Place the left-side footwell and foot peg into position on the footrest. Secure with two cap screws. Tighten to 20 ft-lb. 18. Connect the gas hose to the fuel pump; then connect the vacuum hose. Secure with hose clamps. CD797A 21. Install the front body panel and the front rack. 22. Install the side panels. 23. Install the battery connecting the positive cable first; then the negative cable. 24. Pour the correct amount of recommended oil into the engine/transmission filler hole; install the filler plug. 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 CD766A 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. www.mymowerparts.com 3-165 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (H2 Models) Removing Engine/Transmission.......................... 3-166 Top-Side Components......................................... 3-170 Removing Top-Side Components ....................... 3-170 Servicing Top-Side Components......................... 3-174 Installing Top-Side Components ......................... 3-182 Left-Side Components ........................................ 3-188 Removing Left-Side Components ....................... 3-188 Installing Left-Side Components ......................... 3-191 Right-Side Components ...................................... 3-194 Removing Right-Side Components..................... 3-194 Servicing Right-Side Components ...................... 3-196 Installing Right-Side Components....................... 3-197 Center Crankcase Components.......................... 3-199 Separating Crankcase Halves............................. 3-199 Disassembling Crankcase Half ........................... 3-200 Servicing Center Crankcase Components.......... 3-202 Assembling Crankcase Half ................................ 3-209 Joining Crankcase Halves................................... 3-211 Installing Engine/Transmission............................ 3-213 2. Remove the front rack, gauge pod, footwells and footrests; then remove the front body panel (see Section 8). 3. Disconnect the IAT sensor connector; then loosen the clamp securing the inlet air boot to the throttle body and remove the air filter housing assembly. GZ013 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. GZ091A 4. Using an absorbent towel, clean any spilled gasoline; then press the gasline hose connectors and remove from the fuel rails. AT THIS POINT If the technician’s objective is to service front Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame. AT THIS POINT If the technician’s objective is to service/replace 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 and tool tray; then remove the negative battery cable. www.mymowerparts.com 3-166 GZ124 5. Disconnect the TPS connector (A), MAP sensor connector (B), and ISC valve connector (C) from the throttle body; then route the harness and connectors away from the engine. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ094A NOTE: Using a suitable marker, mark the locations of any ties that are removed to relocate wiring out of the way. GZ107 8. Disconnect the stator coil connector and the crankshaft position sensor connector; then disconnect the gear shift position switch connector. 6. Loosen the clamps securing the throttle body to the intake manifolds; then remove the throttle body and leaving the throttle cable connected, lay the assembly over the handlebar. 3 GZ069A GZ090B 7. Disconnect the fuel injector wiring connectors; then remove the intake manifolds leaving the injectors installed. GZ368A 9. Loosen the clamps securing the V-belt cooling ducts to the V-belt housing; then disconnect the cooling ducts. GZ106 www.mymowerparts.com GZ037 3-167 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ103B GZ099A 10. Remove the E-clips securing the shift linkage to the shift lever and shift shaft; then remove the shift linkage. Account for two bushings and two flat washers. 14. Remove the front and rear spark plug wires from the spark plugs; then disconnect the primary wire connectors from the coils and remove the coils from the left side of the frame. 11. Remove the cap screws securing the rear driveshaft yoke flange to the rear output flange. GZ071A GZ374 15. Remove the cap screw securing the engine and harness grounds to the engine. 12. Remove the exhaust pipe springs at the muffler and remove the muffler. Account for the grafoil seal. GZ064A GZ372 13. Remove the nuts securing the rear exhaust pipe to the cylinder; then remove the springs securing the rear exhaust pipe to the front exhaust pipe and remove the rear exhaust pipe. Account for a grafoil seal on the pipe juncture and a seal in the cylinder. www.mymowerparts.com 3-168 16. Remove the cap screws securing the upper bumper support to the frame and swing the bumper forward allowing access to the radiator drain plug. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ068 GZ028 17. Place a suitable drain pan under the radiator; then remove the radiator drain plug. Do not loosen the radiator cap at this time. 3 GZ369A GZ086A 18. Remove the bleed screw from the water pump; then after coolant has drained, apply compressed air to the bleed opening to purge the remaining coolant from the system. Install the bleed screw and radiator drain plug and tighten securely. GZ008 20. Remove the flange nuts from the front and rear engine through-bolts; then rock the engine slightly to relieve motor mount pressure and remove the through-bolts. GZ009A ! WARNING Always wear safety glasses when using compressed air. 19. Remove the coolant hoses from the upper engine coolant outlet pipes; then remove the lower coolant hose from the water pump. GZ118 www.mymowerparts.com 3-169 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ104 21. Rotate the front driveshaft until the output yoke universal joint is in the vertical plane; then raise the front of the engine/transmission until the front drive splines disengage from the differential. GZ123 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. GZ 110A NOTE: The engine/transmission must be removed to service the rear cylinder head, cylinder, and piston. Removing Top-Side Components A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft GZ117A 22. Fold the front drive line up and secure against the front of the engine; then lift the engine clear of the mountings and remove from the right side of the frame. www.mymowerparts.com 3-170 1. Remove the timing inspection plug, spark plugs, and magneto housing cover; then install the 10 mm cap screw (left-hand threads) in the crankshaft and rotate the desired cylinder to top-dead-center of the compression stroke. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the 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 camshaft plug. Note the location of two alignment pins. GZ027 GZ126A 3 GZ026 NOTE: Timing marks on the rotor/flywheel are stamped with an “F” (front cylinder) and “R” (rear cylinder) adjacent to the mark. GZ162 GZ063 GZ132A 4. Remove the cap screw on the end of the tensioner; then using a screwdriver, turn the tensioner clockwise to remove the tension. Remove the two cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket. GZ059 2. Remove the tappet covers on the cylinder being serviced. The tappets should not have pressure on them. www.mymowerparts.com 3-171 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ200 CC266D 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. NOTE: Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase. NOTE: Care should be taken not to drop the C-ring into the crankcase. 8. Remove the five nuts securing the cylinder head to the cylinder; then remove the four cylinder head cap screws and washers. NOTE: Removing the starter will simplify removal of the front cylinder base nuts. GZ155 6. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft. GZ154A 7. While holding the chain, slide the sprocket and camshaft out of the cylinder head. www.mymowerparts.com 3-172 GZ136A GZ132B 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ151 GZ140A 12. Remove the two nuts securing the cylinder to the crankcase. 3 GZ161 10. If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the second cylinder to top-dead-center of the compression stroke; then repeat steps 2-10 on the other cylinder head. GZ141A 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. C. Cylinders D. Pistons NOTE: Steps 1-10 in the preceding sub-section must precede this procedure. GZ160A 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. 11. Remove the cap screws securing the water hose union to the cylinder; then remove the union from the cylinder. Account for an O-ring. GZ142 www.mymowerparts.com 3-173 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! 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. GZ144 A. Starting with the top ring, slide one end of the ring out of the ring-groove. To service cylinder, see Servicing Top-Side Components sub-section. B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT ! CAUTION AT THIS POINT 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. To service piston, see Servicing Top-Side Components sub-section. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. Servicing Top-Side Components NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. GZ145 15. Using the Piston Pin Puller, 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: Support the connecting rod with rubber bands or a piece of hose to avoid damaging the rod or install the Connecting Rod Holder. 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. 2. Place the valve cover on the Surface Plate 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. GZ146A www.mymowerparts.com 3-174 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! 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. CC130D ! 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. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator. 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. 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. CC132D 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. 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 3-175 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. 4. Maximum “wobble” deflection must not exceed 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. 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. 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) 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. www.mymowerparts.com 3-176 2. Acceptable outside diameter range must be within specifications. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. CC144D 2. Insert each valve into its original location. 3 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. 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 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. 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. 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 PISTON ASSEMBLY 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. NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. Measuring Piston-Ring End Gap (Installed) 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. 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. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. www.mymowerparts.com 3-177 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. Installing Piston Rings 1. Install the expander spring making sure the ends are aligned on the wire; then install the oil ring with the ring gap 90° from the spring gap and the marking “E TOP” directed toward the top of 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. GZ168 ATV-1069 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. www.mymowerparts.com 3-178 GZ169A 2. Install the second compression ring with the marking “E TOP” directed toward the top of the piston. 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 GZ167 3. Install the first (unmarked) compression ring; then rotate the rings so the ring gaps are approximately 180° apart and orientated to the piston pin. Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result. 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. GZ187A ! 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 ! 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. 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 Inspecting 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. www.mymowerparts.com 3-179 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. 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. Inspecting Cylinder CC390D 4. If any measurement exceeds the limit, replace the cylinder and piston. Measuring Camshaft Runout 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. 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. CC283D 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 #320 grit ball hone. www.mymowerparts.com 3-180 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV1013A CC145D 2. The lobe heights must not exceed minimum specifications. 6. If clearance is excessive, measure the journals of the camshaft. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 3 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. 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 (Front Camshaft Only) 1. Inspect the spring and drive pin for damage. 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. CF061A 4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. 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. www.mymowerparts.com 3-181 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF060A 2. If damaged, the camshaft must be replaced. GZ159 3. Lubricate the inside wall of the cylinder; then using a ring compressor, 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. Installing Top-Side Components ! CAUTION A. Pistons B. Cylinders The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. 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 arrow points toward the exhaust of the respective cylinder. GZ142 4. Loosely install the two nuts securing the cylinder to the crankcase. NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10. GZ166 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. GZ141A www.mymowerparts.com 3-182 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the four cylinder head cap screws with washers. Tighten only until snug. GZ160A 5. Install the coolant hose onto the crankcase union and tighten the clamp. GZ132B 9. Loosely install the five cylinder head nuts. C. Cylinder Head D. Valve Cover NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 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. 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) to 40 ft-lb; then tighten the 8 mm nut (from step 9) to 18 ft-lb. Using a crisscross pattern, tighten the 6 mm nuts (from step 9) to 8 ft-lb. Tighten the two cylinder-to-crankcase nuts (from step 4) securely. NOTE: If both cylinders have been removed, repeat steps 1-10 for the remaining cylinder. 11. With the timing inspection plug removed and the chains held tight, rotate the crankshaft until the front 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. GZ161A 7. Place a new head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder while guiding the cam chain through the cylinder head. 732-307B www.mymowerparts.com GZ151 3-183 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. GZ130 ! CAUTION NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. If any of the above factors are not as stated, go back to step 11 and carefully proceed. 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. 15. Place the tab-washer onto the sprocket making sure it covers the pin in the alignment hole. 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. 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. GZ190A 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. 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. GZ195 www.mymowerparts.com 3-184 GZ190B FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 17. Keeping tension on the opposite cam chain, 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 10 ft-lb. Bend the tab to secure the cap screw. ! CAUTION NOTE: Note the position of the alignment marks on the end of the camshaft. They must NOT be parallel with the valve cover but offset slightly to the rear (approximately 5°). 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. Failure to keep tension on any loose cam chain may cause severe engine damage. GZ189A GZ193 18. Rotate the crankshaft until the first cap screw (from step 16) can be tightened; then tighten to 10 ft-lb. Bend the tab to secure the cap screw. AT THIS POINT Return the engine to TDC on the front cylinder making sure the cam lobes are directed downward to ensure correct starting point for step 19. 19. Keeping tension on the rear cam chain, rotate the engine forward 270° until rear piston is at TDC indicated by timing mark R. GZ189B 21. 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. GZ060 20. 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. 732-307B A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks offset 5° from the valve cover mating surface. www.mymowerparts.com 3-185 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 19 and carefully proceed. 22. Place tab-washer onto the sprocket making sure it covers the pin in the alignment hole. GZ193 ATV-1027 ! CAUTION CD465 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. 25. Rotate the crankshaft until the first cap screw (from step 23) can be addressed; then tighten to 10 ft-lb. Bend the tab to secure the cap screw. 23. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug. GZ194 26. Place the C-rings into position in their grooves in the cylinder heads. GZ195 24. 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 10 ft-lb. Bend the tab to secure the cap screw. CC012D www.mymowerparts.com 3-186 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 27. Install the cylinder head plugs in the cylinder heads with the open end facing downward and toward the inside. 30. 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. ! CAUTION The open end of the plug must be positioned downward. GZ201 CD468 28. 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. 3 CD471 31. 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 30. 29. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws. GZ199 32. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder heads. www.mymowerparts.com CD469 3-187 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ202 GZ208 33. Lubricate the camshaft journals and lobes with engine oil; then place the valve cover into position. 38. If removed, install the spark plugs. Tighten securely. 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 GZ206 NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 34. Install the top side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. 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 A. Magneto Cover/Stator Coils B. Water Pump C. Shifter Assembly D. Rotor/Flywheel/Starter Clutch E. Speed Sensor/Trigger Assembly CC003D 35. In a crisscross pattern starting from the center and working outward, tighten the cap screws on both valve covers securely. 36. Adjust valve/tappet clearance (see Section 2). 37. Place the tappet covers into position making sure the O-rings are properly installed. Tighten the cap screws securely. www.mymowerparts.com 3-188 1. Remove the cap screws securing the magneto cover to the crankcase; then remove the magneto cover. Account for the gasket. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ212A AT THIS POINT GZ216 NOTE: The puller has left-hand threads. To replace stator coils/crankshaft position sensor, see Section 5. 2. Remove the starter motor, starter driven gear (A), starter countershaft bushing (B), and starter countershaft gear (C); then remove the starter gear shafts (D) noting that the longer shaft is nearest the starter. 3 GZ217 5. With the flywheel key removed, remove the starter ring-gear and spacer washer. GZ224A NOTE: The starter is not serviceable and must be replaced as a complete assembly. 3. Remove the rotor/flywheel nut; then install the appropriate crankshaft protector into the crankshaft. GZ226 PR440 4. Install Magneto Rotor Remover Set and loosen the rotor/flywheel; then remove the crankshaft protector and rotor/flywheel from the crankshaft. Account for the flywheel key. GZ249 www.mymowerparts.com 3-189 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the hose clamps from the water pump; then remove the coolant hoses from the water pump outlets and coolant pipes. GZ233A GZ218 9. Remove the nut (A) from the shift cam stopper bolt (B); then remove the cam stopper spring (C). Account for a flat washer (D). 7. Remove the two cap screws securing the water pump to the crankcase; then remove the water pump. Account for an O-ring. GZ236A GZ230A 10. Remove the cap screw securing the shift cam plate to the shift cam shaft and remove the shift cam plate; then remove the shift shaft. Account for a washer. NOTE: The water pump is a non-serviceable component and must be replaced as a complete assembly. 8. Remove the cap screws securing the gear shift cover to the crankcase; then remove the gear shift cover. Account for a gasket and washer. 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. GZ234B 11. Remove the cap screws securing the speed sensor housing to the crankcase and remove the housing assembly; then remove the snap ring securing the speed sensor trigger to the shaft and remove the trigger. Account for a gasket. GZ231A www.mymowerparts.com 3-190 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ243 GZ250 3. Install the inner snap ring onto the countershaft; then install the speed sensor trigger, a flat washer, and the outer snap ring. 3 GZ235 12. Remove the cap screws securing the oil filler cover to the crankcase; then remove the cover. Account for an O-ring. GZ250 Installing Left-Side Components GZ253 GZ254 4. Using a new gasket, install the speed sensor housing onto the crankcase and secure with two cap screws. Tighten to 8 ft-lb. 1. Thoroughly clean all gasket material and sealant from mating surfaces. 2. Install a new O-ring on the oil filler cover and coat it with clean engine oil; then install the oil filler cover into the crankcase and secure with the cap screws. Tighten to 8 ft-lb. www.mymowerparts.com GZ232 3-191 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. If removed, install the shift cam stopper on the support; then with the flat washer in place, install the shift cam stopper assembly into the crankcase and tighten to 8 ft-lb. GZ260 GZ255 GZ256 8. Install the shift shaft into the crankcase making sure the washers are properly located; then align the timing reference marks and completely seat the shift shaft. GZ258 6. Install the shift cam stopper spring onto the shift cam stopper and secure with a flat washer and flange nut. Tighten to 8 ft-lb. GZ261 GZ259 7. Install the shift cam plate onto the shift cam shaft and secure with the cap screw. Tighten to 8 ft-lb. www.mymowerparts.com 3-192 9. Apply grease to the lips of the shift shaft seal in the shifter housing; then using a new gasket, install the shifter housing and secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ262 10. Install the spacer washer on the crankshaft; then install the starter ring gear. GZ225 ! CAUTION Make sure the one-way starter clutch is properly engaged with the starter ring gear before installing and tightening the rotor/flywheel nut or damage to the clutch assembly could occur. 12. Install the starter driven and counter gear shafts (D) into the crankcase (longer shaft to the front); then install the starter countershaft gear (C), starter driven gear (A), and bushing (B) making sure the chamfered gear teeth on the countershaft gear are directed outward. GZ249 GZ224A 13. Install the starter motor with a new O-ring lightly lubricated with grease; then tighten the mounting cap screws to 8 ft-lb. GZ226 11. Place the key into the keyway in the crankshaft; then wipe all oil from the crankshaft surface and rotor/flywheel bore and install the rotor/flywheel onto the crankshaft aligning the keyway with the key. Secure with the nut and tighten to 107 ft-lb. GZ251 14. Install the magneto cover using a new gasket and secure with the cap screws. Using the pattern shown, tighten to 8 ft-lb. www.mymowerparts.com 3-193 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ212B Right-Side Components GZ244B 2. Remove the nut securing the movable drive face; then remove the face. Account for a spacer and a flat washer. 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. GZ074 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 D. Centrifugal Clutch 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 and two alignment pins. www.mymowerparts.com 3-194 CD966A 3. Remove the V-belt. 4. Remove the nut securing the fixed driven assembly; then remove the assembly. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR388 5. Remove the fixed drive face. 6. Remove the cap screws securing the V-belt housing to the crankcase; then remove the V-belt housing. Account for two alignment pins. GZ247A NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 8. Remove the one-way clutch from the centrifugal clutch. Note the location of the green dot (or the word OUTSIDE) for installing purposes. 3 GZ246A 7. Remove the cap screws securing the clutch cover; then using a rubber mallet, carefully remove the cover. Account for two alignment pins. GZ247B 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. GZ246B CF085 www.mymowerparts.com 3-195 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 CC596 Always replace the clutch shoes as a complete set or severe imbalance could occur. NOTE: Account for and inspect the clutch housing seal. 10. Remove the two cap screws securing the gear shift position switch; then remove the switch. Account for two contact pins and two springs. ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. CD997 11. Remove the nut (left-hand threads) securing the clutch shoe assembly. 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. DRIVEN PULLEY ASSEMBLY GZ248A Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. www.mymowerparts.com 3-196 NOTE: The driven pulley is a non-serviceable component. If the pulley faces, cam ramps, or sheeve bushing are worn or loose, the pulley must be replaced as an assembly. Do not disassemble the driven pulley. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Right-Side Components 1. Apply silicone to the mating surfaces; then install the gear shift position switch making sure the two contact pins and the two springs are properly positioned. Tighten the cap screws securely. CF088A 4. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase. 5. Apply grease to the outer edges of the clutch housing; then from inside the clutch cover, install the clutch housing into the cover. 6. Install the one-way clutch onto the clutch shoe assembly. CD997 GZ247 GZ240 2. Install the clutch shoe assembly and secure with the flange nut (threads coated with red Loctite #271). Tighten to 221 ft-lb. ! CAUTION When installed correctly, the green alignment dot (or the word OUTSIDE) on the one-way clutch is visible. 7. Place the clutch cover/clutch housing assembly into position on the crankcase; then secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. GZ241 3. Lightly grease the clutch housing seal; then insert the left fixed drive spacer. GZ246B www.mymowerparts.com 3-197 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Making sure the alignment pins are correctly installed, place a bead of silicone sealant on the mating surfaces and install the V-belt housing. Secure with the cap screws tightened to 8 ft-lb. GZ065A 12. Place the V-belt into position on the driven pulley and over the front shaft. GZ263 GZ085 GZ244A 9. Place the driven pulley assembly into position and secure with the nut (coated with red Loctite #271). Tighten to 80 ft-lb. NOTE: The arrows on the V-belt should point forward. 13. 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 flat washer and a nut (threads coated with red Loctite #271). Tighten the nut to 165 ft-lb. GZ066 10. Slide the fixed drive face onto the clutch shaft. 11. Spread the faces of the driven pulley by threading in a cap screw; then when the faces are separated, insert the belt and push down between the faces. GZ075 ! CAUTION Make sure the splines extend beyond the drive face and washer or a false torque reading and spline damage may occur. www.mymowerparts.com 3-198 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR386 GZ264 NOTE: At this point, the cap screw can be removed from between the driven pulley faces. 14. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. 15. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws. Tighten the cap screws to 8 ft-lb. 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. 3 GZ268 2. Remove the cap screws securing the lower crankcase to the upper crankcase halves; then using a rubber hammer, free the lower crankcase and remove. 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. Separating Crankcase Halves 1. Remove the oil strainer cap; then remove the oil strainer. GZ321A 3. Remove the secondary drive assembly; then remove the secondary driven shaft assembly and set aside. Account for one locating ring. www.mymowerparts.com 3-199 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ322B GZ272B Disassembling Crankcase Half NOTE: For steps 1-8, refer to photograph GZ298A. GZ269A NOTE: Do not disassemble these assemblies unless service is required. If disassembled, secondary gear sets will have to be reset for backlash and gear contact (see Servicing Center Crankcase Components in this section). 4. Remove one cap screw from the right-side crankcase and eight cap screws from the left-side crankcase; then using a rubber mallet, separate the crankcase halves leaving all components in the right-side case. Account for a thrust washer on the crankshaft and flat washers on gear shift shaft, countershaft, and reverse idler. Note the location of two alignment pins. GZ298A NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 1. Support the right-side crankcase assembly on suitable support blocks; then carefully remove the crankshaft assembly (A) from the crankcase. GZ271 GZ298 2. Remove the snap ring securing the water pump drive idler (B) to the idler shaft; then remove the drive idler. www.mymowerparts.com 3-200 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ299A GZ276 3. Remove the water pump driven shaft (C). Account for the driven gear and drive pin. 6. Remove two cap screws securing the oil pump in the crankcase and remove the oil pump. 3 GZ304A GZ305 4. Remove the snap ring securing the oil pump driven gear (D) to the oil pump driveshaft; then remove the gear. Account for a drive pin and washer. 7. Remove the driveshaft (G); then remove the countershaft assembly (with shift forks) (H). Account for three flat washers on the countershaft. GZ280A GZ301A 5. Remove the shift fork shaft (E); then remove the gear shift shaft assembly (F). Account for two flat washers. 8. Remove the reverse idler gear (I), shaft bushing, and two washers. www.mymowerparts.com 3-201 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ279 NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. MT011B 3. If installing the existing shaft, start with the shims removed during disassembly or if installing a new shaft, start with approximately 1.0 mm shims at point (D); then install the output drive shaft bearing (E) making sure the locating pin is directed toward the center of the shaft. Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY OUTPUT DRIVE GEARS Initial Set-Up MT012 NOTE: If the secondary output driven shaft is replaced or disassembled, the initial set-up must be performed to establish correct gear tooth contact. If only the secondary output drive shaft or secondary output driven gear are replaced, proceed to Correcting Backlash in this sub-section. 1. Install a new bearing (A) onto the secondary driven shaft (B) making sure the bearing locating groove is directed away from the driven gear splines. MT008A 4. Install a new seal (F), output yoke (G), and nut (H) and tighten to 59 ft-lb. MT011A 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft. www.mymowerparts.com 3-202 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MT008B NOTE: Do not use a new lock nut at this time as this procedure may have to be repeated. GZ396 3. While rocking the drive bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Place the assembled shaft into the left crankshaft case; then lightly coat the gear teeth with machinist's lay-out dye. Rotate the shafts through several rotations in both directions. Gear contact should extend from the root to the top of the gear teeth. 3 GZ398 4. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). Correcting Backlash MT016A 6. To adjust tooth contact, use the following chart to correctly shim the driven shaft. Tooth Contact Shim Correction Contact at Top Increase Shim Thickness Contact at Root Decrease Shim Thickness 7. After correct tooth contact is established, proceed to Checking Backlash in this sub-section. Checking Backlash 1. Install the drive bevel gear assembly and driven bevel gear/output shaft assembly into the crankcase bottom cover. 2. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear. 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. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. 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 OIL PUMP ASSEMBLY Disassembling and Inspecting 1. Remove the oil pump cover; then remove the gerotor set, shaft, and pin (see Disassembling Crankcase Half in this section). www.mymowerparts.com 3-203 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the crankcase for securing, discoloration, or cracks in the gerotor bore. If scored, crankcase assembly must be replaced. GZ354A 6. Remove the oil seal from the oil pump cover. GZ357 3. Inspect the gerotor set for scoring, discoloration, or cracks; then using a feeler gauge, check the inner to outer rotor clearance. If measurements exceed specifications, the gerotor set must be replaced. GZ365 Assembling 1. Install a new oil seal into the oil pump cover; then coat the lips of the seal with grease and install the pump driveshaft from the seal side. GZ355 4. Inspect the oil pump cover for scoring, discoloration, or cracks. Replace if damaged. GZ359 GZ358 5. Inspect the oil pump driveshaft and drive pin for excessive wear or grooving. Replace as required. www.mymowerparts.com 3-204 2. Noting the reference dots on the gerotor set, separate the inner rotor from the outer rotor and with the reference dot directed toward the oil pump cover, place the rotor on the shaft; then install the drive pin and push the shaft into the rotor. 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. GZ356 CC290D 2. Maximum diameter must not exceed specifications. GZ363 3. With the outer rotor reference dot directed toward the oil pump cover, install the rotor onto the inner rotor. 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. GZ360 4. Place a new O-ring seal on the outside of the oil pump cover. The oil pump assembly is now ready for assembly into the crankcase. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. 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. 2. Acceptable width range must be within specifications. www.mymowerparts.com GZ362 3-205 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Crankshaft (Runout) COUNTERSHAFT 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. GZ281A ! CAUTION 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 3-4. Measuring Crankshaft (Web-to-Web) 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. Disassembling 1. Remove the shift forks noting the positions for assembling; then remove the high driven gear outer washer, high driven gear, high driven gear bearing, high driven gear bushing, and high driven gear inner washer. 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. GZ283A 2. Remove the drive gear; then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft. ATV-1017 2. Acceptable width range must be within specifications. www.mymowerparts.com 3-206 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ296 GZ320 3 GZ312 GZ319 3. Remove the reverse driven gear dog. GZ318A GZ313A 4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear. 6. Remove the low driven gear. Account for a bearing, bushing, and thrust washer. GZ316 GZ314 5. Remove the reverse driven washer; then remove the low driven gear locking washer. www.mymowerparts.com 3-207 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320B 3. Install the reverse driven bushing and bearing; then install the reverse driven gear. GZ317A GZ286A GZ318 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ287 4. Install the outer reverse driven washer; then secure the reverse driven gear assembly with a snap ring. GZ319B GZ288A www.mymowerparts.com 3-208 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Install the two drive gear washers and the shift forks. The countershaft is now ready for installation. Assembling Crankcase Half GZ314 5. Install the reverse driven gear dog onto the countershaft and secure with a snap ring. 1. Install the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws. Coat the threads with blue Loctite #243 and tighten securely to 8 ft-lb. 3 GZ305 GZ313A 2. Install a flat washer, drive pin, and drive gear onto the oil pump shaft; then secure with a snap ring (flat-side away from the gear). GZ312 6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F). www.mymowerparts.com GZ347 3. Install the water pump drive gear, driveshaft, and drive pin; then install the countershaft into the crankcase and secure with a snap ring (flat-side away from the bearing). GZ283B 3-209 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ304A GZ332 GZ328A GZ333 4. Install the countershaft gear onto the countershaft and secure with a snap ring (flat-side away from the gear). 7. Install the gear shift shaft into the crankcase making sure the flat washer is in place on the gear shift position switch end and the bearing assembly on the gear shift stop end. 5. Using rubber bands to support the connecting rods, carefully install the crankshaft assembly into the crankcase. GZ334A GZ330 NOTE: It will be necessary to rotate the crankshaft back and forth to engage the teeth of the oil pump and countershaft gears. 6. Install the driveshaft; then with a flat washer on each end of the reverse idler assembly, install into the crankcase. GZ335 www.mymowerparts.com 3-210 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Place two flat washers on the drive gear end of the countershaft and one flat washer on the high driven gear end; then with shift forks and shift fork shaft, install the countershaft assembly into the crankcase. Joining Crankcase Halves 1. Using rubber bands, support the connecting rods to align with the cylinder bores. GZ280A GZ340 2. Coat both sides with motor oil; then install the spacer washer on the crankshaft with the radius directed toward the crankshaft. GZ336 9. Engage the shift forks into the gear shift shaft and push the shift fork shaft into the crankcase. GZ341 3. Install the two alignment pins; then apply a thin bead of silicone sealant to the crankcase mating surface. GZ339 AT THIS POINT Proper transmission shifting should be verified by turning the gear shift shaft to select High, Low, Neutral, and Reverse while rotating the input shaft and observing the countershaft rotation. The right-side crankcase is now ready for installation to the left-side crankcase. www.mymowerparts.com GZ345A 4. Carefully join the crankcase halves by placing the left-side crankcase onto the assembled right side. Secure with the cap screws (eight left side and one right side). 3-211 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ342 GZ322B 5. Tighten the cap screws to 8 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no binding. 7. Install two locating pins into the upper crankcase assembly; then apply a thin bead of silicone sealant to the lower crankcase cover. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. GZ322A GZ375A NOTE: Cap screw number eight (8) is installed from the right side. NOTE: If the secondary drive/driven assemblies have been disassembled, refer to Servicing Center Crankcase Components for proper gear tooth contact and backlash. 6. Install the locating ring in the crankcase assembly; then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly. GZ269A www.mymowerparts.com 3-212 GZ265 8. Carefully place the lower crankcase cover onto the joined crankcase halves; then secure with the cap screws. Tighten the 6 mm cap screws to 8 ft-lb and the 8 mm cap screws to 20 ft-lb. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ321 GZ110A 9. Install the oil screen; then apply a thin bead of silicone sealant to the oil strainer cap and secure with the cap screws. Tighten to 8 ft-lb. 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. Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. Turn the front driveline to place the output drive yoke universal joint in the horizontal plane; then secure the driveshaft to the right and against the engine. 3 GZ119 4. Align the rear output drive flange and the rear driveshaft yoke flange and install the cap screws. Tighten to 20 ft-lb. 5. Align the engine with the mounting brackets and install the through-bolts with flat washers; then install the flange nuts and tighten to 45 ft-lb. 6. Connect the coolant hose and tighten the clamps securely. 7. Secure the engine and harness grounds to the engine and tighten the cap screw to 8 ft-lb. GZ117A 2. Install the engine/transmission into the frame from the right side. 3. Rotate the driveshaft 90°; then lift the front of the engine sufficiently to engage the splined shaft into the front differential. Lower the front of the engine. GZ064A 8. Install the ignition coils and tighten the cap screws to 7 ft-lb; then connect the primary wires, grounds, and spark plug caps. 9. Connect the stator coil connector and crankshaft position sensor connector; then connect the gear shift position switch connector. www.mymowerparts.com 3-213 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the intake manifolds and tighten to 8 ft-lb; then install the throttle body and secure with the hose clamps. GZ069A GZ106 GZ368A 10. Install the front the rear exhaust pipes with new grafoil seals and tighten the retaining nuts to 20 ft-lb; then install the muffler and connect all exhaust juncture springs. GZ107 GZ090B GZ099A 12. Connect the fuel injector, TPS connector (A), MAP sensor connector (B), and ISC valve connector (C). GZ372 www.mymowerparts.com 3-214 GZ094A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Install the shift linkage with bushings and secure with E-clips. 16. Install the V-belt cooling duct and boots. Tighten securely. 14. Connect the gasline hose connectors to the fuel rails; then install any nylon ties that were removed during disassembly. 17. Install the front body panel, footrests, foot wells, and front rack; then install the upper bumper support-to-frame cap screws (see section 8). 18. Connect the negative battery cable; then secure the battery with the tool tray and install the seat. 19. Pour in the proper quantities of engine/transmission oil and coolant; then start the engine and warm up to operating temperature. 20. Check for fluid leaks; then shut off engine and check fluid levels (see Section 2). GZ124 15. Install the air filter housing and secure to the throttle body with a hose clamp; then connect the IAT sensor connector. 3 GZ013 www.mymowerparts.com 3-215 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 Fuel/Lubrication/Cooling ......................................... 4-2 Carburetor Specifications (400/500)........................ 4-2 Carburetor Schematics (400/500) ........................... 4-2 Carburetor (400/500)............................................... 4-2 Electric Choke (400/500)......................................... 4-7 Electronic Fuel Injection (EFI Models) .................... 4-8 Throttle Cable Free-Play ....................................... 4-10 Engine RPM (Idle)................................................. 4-11 Gas Tank ............................................................... 4-11 Oil Filter/Oil Pump ................................................. 4-12 Testing Oil Pump Pressure.................................... 4-12 Oil Cooler (400/700/H2 Models)............................ 4-12 Liquid Cooling System (500/H1/H2 Models) ......... 4-13 Electric Fuel Pump/Fuel Level Sensor (EFI Models) ...................................................... 4-18 Vacuum Pulse Fuel Pump (500)............................ 4-20 Troubleshooting (400/500)..................................... 4-21 Troubleshooting (EFI Models) ............................... 4-21 4-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel/Lubrication/ Cooling Carburetor Schematics (400/500) 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 1. SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. Description p/n Oil Pressure Test Kit 0644-495 Seal Removal Tool 0644-072 Tachometer 0644-275 Electric Choke Test Harness 0444-247 KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Screw Spring Vacuum Piston Spring Seat Jet Needle Needle Jet Jet Holder Main Jet Slow Jet Starter Jet Float Valve Clip 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Float Float Pin Pilot Screw Spring Washer O-Ring Idle Adjust Screw Washer Spring Plate Screw Electric Choke Choke Cover 27. Float Chamber Assy 28. O-Ring 29. Screw 30. Spring 31. Diaphragm Assy 32. Pump Housing 33. U-Ring 34. Screw 35. Screw 36. Throttle Cable 37. Cover 38. Screw 39. Vent Hose NOTE: Special tools are available from the Arctic Cat Service Parts Department. Carburetor Carburetor Specifications (400/500) (400/500) Item Carburetor ! WARNING 400 Keihin CVK34 0740-600 500 Keihin CVK36 Main Jet 138 138 Slow Jet 40 40 Pilot Screw Setting (turns) 1 3/4 1 3/4 Jet Needle NAZG NFKG Idle RPM (engine warm) 1250-1350 1250-1350 Starter Jet 75 85 Float Arm Height 17 mm (0.7 in.) 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) 3-6 mm (1/8-1/4 in.) 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 1. Remove the seat. 2. As necessary to access the carburetor, remove the air-intake snorkel, the air filter housing cover, or the air filter 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. www.mymowerparts.com 4-2 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 PR154B 6. Remove the throttle cable from the actuator arm. CH015D 2. Remove the vacuum piston assembly from the carburetor body. Account for a spring, spring seat, and the jet needle. 4 PR162C 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). PR162B 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 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. CLEANING AND INSPECTING CC752 6. Lift the float assembly from the carburetor. Account for the float valve. 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 clean, hot water. CC753 NOTE: Note the locations of the jets, pilot screw, and holder for disassembling procedures. www.mymowerparts.com 4-4 3. Wash all non-metallic components with soap and water. Rinse thoroughly. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 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. 10. Inspect the slow jet and main jet for obstructions or damage. NOTE: If the slow jet is obstructed, the mixture will be extremely lean at idle and part-throttle operation. CC761A 3. Install the slow jet. Tighten securely. 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. 5. Place the float assembly (with float valve) into position and secure to the carburetor with the float pin. 11. Inspect the float valve for wear or damage. 4 12. Inspect the carburetor mounting flange for damage and tightness. ASSEMBLING 1. Thread 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 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 www.mymowerparts.com 4-5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC749 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. CH015D INSTALLING 1. Connect the gas and vent hoses onto the carburetor. 2. Connect the electric choke lead to the wiring harness. CC748 ! 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. CC740A 3. Place the throttle cable into position and secure by tightening the outer jam nut. 8. Place the jet needle, spring seat, and spring into the vacuum piston; then place the assembly down into the carburetor. PR162B 4. Connect the throttle cable to the actuator arm. CC746 9. Place the top cover into position; then secure with the Phillips-head screws. Tighten securely. www.mymowerparts.com 4-6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR162C KC328A 5. Place the throttle actuator cover into position on the carburetor; then secure with the screw. 2. With the choke at room temperature (approximately 70° F), measure plunger extension. Measurement (A) should be 18.6-19.1 mm. 4 PR154B 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. 8. As necessary, secure the air-intake snorkel, the air filter housing cover, or the air filter housing. KC328B 3. Connect Electric Choke Test Harness to the choke connector and a suitable 12 DC volt power supply for 2-3 minutes. Disconnect the power and measure plunger extension. Measurement (B) should be 22.1-23.4 mm. 9. Install the seat. Electric Choke (400/500) REMOVING 1. Disconnect the electric choke connector from the wiring harness; then remove the screw securing the choke body to the carburetor. 2. Carefully remove the choke assembly from the carburetor taking care not to force the plunger from the carburetor body. INSPECTING/TESTING 1. Inspect the plunger (A) for scoring or scratches, the needle (B) for damage to the tip, the spring (C) for breakage, and the O-ring (D) for breaks. KC328C 4. If the choke is damaged or the measurements are not within specifications, the choke must be replaced. INSTALLING 1. Lightly lubricate the O-ring on the choke body; then carefully insert the choke assembly into the carburetor being careful not to damage the plunger. www.mymowerparts.com 4-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Secure the choke with the screw and tighten securely; then connect the choke connector to the wiring harness. Electronic Fuel Injection (EFI Models) ! 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 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 Electric Fuel Pump/Fuel Level Sensor (EFI Models) in this section. FI081B 5. Slowly disconnect the gasline hose connector from the fuel rail. ! WARNING Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting. 2. Check for a flashing EFI icon on the LCD. If EFI is flashing, see ECU Error Codes (EFI Models) 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). REMOVING (H1 Models) 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. 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. 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. 2. Disconnect the battery; then remove the seat. 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. FI089A www.mymowerparts.com 4-8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. GZ091A 3. Loosen the clamp on the throttle body intake boot; then remove the air filter housing from the ATV. FI104A 11. Use tape to cover and seal the intake opening. 4. Disconnect the three wiring connectors from the sensors on the throttle body; then remove the cap screws securing the throttle body to the intake manifold. ! 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. 4 REMOVING (H2 Models) ! WARNING Whenever the gasline hoses are removed (other than for pressure testing), the battery must be disconnected to prevent inadvertent activation of the electronic fuel pump. 1. Remove the front rack and body panel (see Section 8). GZ094B 2. Disconnect the wires from the IAT sensor; then loosen the clamp and remove the inlet air boot from the air filter housing. GZ381A 5. Remove the throttle arm cover and disconnect the throttle cable; then remove the throttle body from the ATV. GZ379 www.mymowerparts.com 4-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the three wiring connectors to the sensors; then install the air filter housing and connect all hoses. Tighten all clamps securely. GZ383A 6. Use tape to cover and seal the intake opening. ! CAUTION GZ094B 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 (H1 Models) 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. 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. INSTALLING (H2 Models) 1. Connect the throttle cable to the throttle body; then remove the tape from the intake manifold and install the throttle body using a new O-ring. Tighten the cap screws securely. www.mymowerparts.com 4-10 GZ381A GZ091A 3. Connect the wiring connector to the IAT sensor 4. Install the front rack and body panel (see Section 8). 5. Install the seat making sure it locks securely in place. Throttle Cable Free-Play 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. AL611D FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Turn the adjuster until the throttle cable has proper free-play of 3-6 mm (1/8-1/4 in.) at the lever. 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. REMOVING 1. Remove the seat. ATV-0047 3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. 2. Remove the rear rack and fenders (see Section 8). 3. Disconnect the hose from the fuel pump to the carburetor/throttle body. 4. Remove the cap screws securing the gas tank to the frame. Engine RPM (Idle) 5. Disconnect the fuel gauge connector; then remove the gas tank. NOTE: The idle RPM is not adjustable on the EFI models. To properly adjust the idle RPM, a tachometer is necessary. To adjust idle RPM, use the following procedure. NOTE: The idle adjustment screw is located on the right-hand side of the carburetor. 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. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all gas tank components with parts-cleaning solvent. 2. Inspect all hoses for cracks or leaks. 3. Inspect tank cap and tank for leaks, holes, and damaged threads. 4. Remove the fuel level sensor/fuel pick-up assembly and inspect the fuel level sensor and fuel screen. NOTE: If the fuel level sensor has failed or may be faulty, see Electric Fuel Pump/Fuel Level Sensor (EFI Models) in this section. INSTALLING 1. Install the fuel level sensor/fuel pick-up assembly. 2. Place the gas tank into position in the frame; then install the cap screws. Tighten securely. AF920D ! WARNING Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM. 3. Connect the gas hose from the carburetor/throttle body; then connect the fuel gauge connector. 4. Install the vent hose; then fill the gas tank with gasoline. 5. Start the engine and inspect for leakage. 6. Install the rear fenders and rack; then install the seat making sure it latches securely. www.mymowerparts.com 4-11 4 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 CF264B NOTE: The engine must be warmed up to the specified temperature for this test. 1. Connect the Tachometer to the engine or utilize the LCD (if equipped). 2. Connect the Oil Pressure Test Kit to the oil filter drain plug (400/500), the oil pressure test port (H1 models), or the oil cooler to oil filter line (H2 models). GZ388A 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. With the oil temperature at 60° C (140° F), the oil pressure gauge must read as specified. 400/500/700 1.05-1.76 kg/cm² (15-25 psi) KC195B H2 Models 0.7-1.4kg/cm² (10-20 psi) NOTE: If the oil pressure is lower than specified, check for low oil level, defective oil pump, or restricted oil cooler. 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. Oil Cooler (400/700/H2 Models) CD457D REMOVING NOTE: It is not necessary to drain the engine oil for this procedure. www.mymowerparts.com 4-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 4. Remove the upper and lower coolant hoses. 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. AL651D 3. Remove the oil cooler from the frame. INSTALLING 1. Place the cooler into position in the frame. 2. Secure the cooler to the frame with the cap screws and grommets. 3. Install the hoses onto their respective fittings and secure with the clamps. Liquid Cooling System (500/H1/H2 Models) 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. CC863 4 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. Installing 1. Position the fan/fan shroud assembly on the radiator; then secure with existing hardware. ! CAUTION 2. Place the radiator with grommets and collars into position on the frame; then install the cap screws and nuts. Tighten securely. 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. 3. Install the upper and lower coolant hoses; then secure with hose clamps. RADIATOR 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). www.mymowerparts.com 4-13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the thermostat for corrosion or spring damage. 2. Using the following procedure, inspect the thermostat for proper operation. A. Suspend the thermostat in a container filled with water. AF734D 4. Install the front bumper and front fender panel. 5. Install the front rack. 6. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. 7. Connect the fan wiring to the main wiring harness. 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). D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear. HOSES/THERMOSTAT Removing (500/H1 Models) 1. Drain approximately one quart 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. Removing (H2 Models) NOTE: The thermostat is located in a housing in-line with the upper radiator hoses under the air filter housing. NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. Installing (500/H1 Models) 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. 3. Slide the upper hose onto the thermostat housing and radiator. Secure with the two hose clamps. 4. Install the lower coolant hose onto the water pump housing and radiator. Secure with the two hose clamps. 5. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. Installing (H2 Models) 1. Place the thermostat and O-ring into the thermostat housing; then secure the thermostat housing together with the four machine screws. GZ036A 1. Drain approximately one quart of coolant from the cooling system. 2. Remove the machine screws securing the thermostat housing together. Remove the thermostat and account for an O-ring. 2. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. COOLING FAN Removing 1. Remove the radiator (see Liquid Cooling System in this section). 2. Remove the fan assembly from the radiator. www.mymowerparts.com 4-14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Assembling/Installing 1. Position the fan assembly on the radiator; then secure with existing hardware. NOTE: Treat seals and O-rings with clean antifreeze for initial lubrication. NOTE: The fan wiring must be in the upper-right position. 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. 2. Install the radiator. WATER PUMP (500 - Manual Transmission) 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. Removing/Disassembling KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Case Cap Screw Gasket O-Ring Impeller Mechanical Seal Seal Cap Screw Washer Washer Cap Screw Cap Screw Shaft w/Bearing 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. 14. Joint 15. Pin 0738-290 1. Drain the coolant. 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. 4 WATER PUMP (500 - Automatic Transmission/H1 Models) NOTE: On the H1 models, the water pump is a non-serviceable component. It must be replaced as an assembly. 3. Remove the impeller cap screw, washer, and gasket. NOTE: On the 500 when servicing the water pump, it will be necessary to install a new oil seal and a new mechanical seal. 4. Remove the mechanical seal using this procedure. Removing A. Tap the tip of a small sheet metal screw into the inner-metal edge of the seal. 1. Remove the radiator cap; then remove the water pump drain and drain the coolant. 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. 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. www.mymowerparts.com 4-15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Loosen the hose clamps and slide the clamps away from the hose ends approximately 2 in.; then remove both hoses from the water pump. 5. Using an impact driver, loosen but do not remove the two Phillips-head cover screws. CC772 Cleaning and Inspecting CC785A 6. Remove the two cap screws securing the water pump to the engine; then remove the water pump. 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. 2. Inspect the impeller/shaft for corrosion or damage. 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 Disassembling 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, remove the mechanical seal and the oil seal from the bearing housing. 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. www.mymowerparts.com 4-16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 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. 6. 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. WATER PUMP (H2 Models) 1. Secure the water pump to the engine with the two cap screws tightened securely; then tighten the two Phillips-head cap screws securely. NOTE: The water pump is a non-serviceable component. It must be replaced as an assembly. Removing 1. Remove the coolant drain plug; then remove the radiator cap and drain the coolant into a suitable container. 4 CC786A GZ093A NOTE: Always use a large container and have sufficient floor drying material available when draining the coolant in case of coolant spillage. 2. Remove the coolant hoses from the water pump; then remove two cap screws securing the water pump to the crankcase. CC785A 2. Connect the two coolant hoses to the water pump and secure with the clamps. Tighten securely. 3. 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 20 ft-lb. 4. Fill the engine/transmission with the proper amount of recommended oil. 5. Fill the cooling system with the proper amount of recommended coolant. GZ230A 3. Remove the water pump from the engine. www.mymowerparts.com 4-17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing 1. Install a new O-ring onto the water pump and lightly coat with clean engine oil. Electric Fuel Pump/ Fuel Level Sensor (EFI Models) The electric fuel pump and fuel level sensor are not serviceable components. If either component fails, it must be replaced. TESTING ! WARNING GZ252C 2. Install the water pump assembly onto the engine aligning the flat drive on the water pump to the slot in the driveshaft. 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 GZ252D ! CAUTION Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting. Do not force the water pump housing into the crankcase or sever engine damage may occur. 3. Secure the water pump with the two cap screws and tighten securely; then connect the coolant hoses and secure with hose clamps. 4. Tighten the coolant drain plug securely; then fill the cooling system with appropriate mixed coolant and install the radiator cap. 5. Start the engine and check for coolant leaks; then add coolant if necessary to proper level. ! 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 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). 4. If the pump is not running, disconnect the fuel pump/tank sensor connector by reaching under the rear rack from behind. www.mymowerparts.com 4-18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. REMOVING 1. Remove the rear rack and fenders (see Section 8); then disconnect the power supply/fuel hose 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. ATV2116 NOTE: If readings are erratic, clean the resistor wiper and resistor with clean alcohol and retest. If still not correct, replace the fuel level sensor. 4. To replace the fuel level sensor, use the following procedure. A. Disconnect the two-wire connector (A); then press the fuel level sensor toward the top of the fuel pump to release it from the mounting slot (B). 4 ! 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. 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 level sensor by connecting a multimeter (A) to the fuel level 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). FI460A B. Engage the tabs (C) of the fuel level 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. www.mymowerparts.com 4-19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX190 CD815 3. Rotate the fuel pump until the match marks align; then install the mounting screws and tighten securely using a crisscross pattern. 2. Start the engine. Fuel pump pressure should read 0.18-0.25 kg/cm2 (2.5-3.5 psi). 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. Vacuum Pulse Fuel Pump CD816 REMOVING 1. Remove the seat; then remove the three clamps securing the gas hoses and vacuum hose and disconnect the hoses. (500) The vacuum pulse fuel pump is not a serviceable component. If the pump fails, it must be replaced. TESTING ! 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. www.mymowerparts.com 4-20 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting (400/500) Problem: Starting impaired Condition 1. 2. 3. 4. Remedy Starter jet obstructed Starter jet passage obstructed Carburetor leaking air Gas contaminated 1. 2. 3. 4. Clean jet Clean passage Replace gasket Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition 1. 2. 3. 4. Remedy Slow jet obstructed - loose Slow jet outlet obstructed Low speed fuel screw setting incorrect Float height incorrect 1. 2. 3. 4. Clean - tighten jet Clean outlet Adjust screw Adjust float height Problem: Medium or high speed impaired Condition 1. 2. 3. 4. 5. 6. Remedy High RPM “cut out” against RPM limiter Main jet obstructed Needle jet obstructed Vacuum piston not operating properly Filter obstructed Float height incorrect 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 4 Problem: Overflow and fuel level fluctuations Condition 1. 2. 3. 4. 5. Remedy Float valve worn - damaged Float valve spring broken Float not working properly Float valve dirty Float height too high - too low 1. 2. 3. 4. 5. Replace valve Replace spring Adjust float height - replace float Clean valve Adjust float height Troubleshooting (EFI Models) Problem: Starting impaired Condition 1. Gas contaminated Remedy 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition 1. TPS out of adjustment Remedy 1. Adjust TPS Problem: Medium or high speed impaired Condition 1. High RPM “cut out” against RPM limiter Remedy 1. Decrease RPM speed www.mymowerparts.com 4-21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System..................................................... 5-2 Specifications .......................................................... 5-2 Battery..................................................................... 5-3 RPM Limiter............................................................. 5-4 Testing Electrical Components ................................ 5-4 Accessory Receptacle/Connector ........................... 5-4 Brakelight Switch (Auxiliary).................................... 5-4 Brakelight Switch (Handlebar Control) .................... 5-5 Oil Temperature and Cooling Fan Switches (400)... 5-5 Coolant Temperature and Cooling Fan Switches (500)..................................................................... 5-6 Engine Coolant Temperature (ECT) Sensor (EFI Models) ....................................................... 5-6 Fan Motor ................................................................ 5-7 Power Distribution Module (PDM) ........................... 5-7 Ignition Coil ............................................................. 5-8 EFI Sensors/Components (EFI Models)................ 5-10 Speed Sensor ....................................................... 5-11 Ignition Switch ....................................................... 5-11 Handlebar Control Switches.................................. 5-12 Front Drive Selector Switch ................................... 5-13 Front Drive Selector Actuator (400/500)................ 5-14 Front Drive/Differential Lock Actuator (H1/H2 Models) .................................................. 5-14 Differential Lock Switch (500)................................ 5-15 Differential Lock Control Switch (H1/H2 Models) .................................................. 5-15 Stator Coil (400/500) ............................................. 5-15 Stator Coil/Crankshaft Position (CKP) Sensor (EFI Models) ...................................................... 5-16 Starter Relay ......................................................... 5-17 Starter Motor ......................................................... 5-18 CDI Unit (400/500) ................................................ 5-22 Electronic Control Unit (ECU) (EFI Models) .......... 5-22 Regulator/Rectifier................................................. 5-22 Headlights ............................................................. 5-22 Taillight - Brakelight ............................................... 5-23 Ignition Timing ....................................................... 5-23 ECU Error Codes (EFI Models)............................. 5-23 Tilt Sensor (EFI Models)........................................ 5-24 Throttle Position Sensor (TPS) (EFI Models) ........ 5-25 Troubleshooting ..................................................... 5-28 www.mymowerparts.com 5-1 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System This section has been organized into sub-sections which show procedures for the complete servicing of the Arctic Cat ATV electrical system. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tool Catalog for the appropriate tool description. Description 0486-219 Fluke Model 73 Multimeter 0644-191 MaxiClips 0744-041 Peak Voltage Reading Adapter 0644-307 Tachometer 0644-275 Test Plug/Error Code List 0444-216 Timing Light 0644-296 NOTE: Special tools are available from the Arctic Cat Service Parts Department. Specifications 400 TRV Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR8E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Ignition Coil Resistance 4000-6000 ohms (primary) Less than 1 ohm (terminal to terminal) (secondary) 2900-3400 ohms (high tension plug cap removed - to ground) (primary) (secondary) Ignition Coil Peak Voltage Stator Coil Resistance (primary/CDI) Peak Voltage (trigger) (charging) (signal) (trigger) (signal) (no load) AC Generator Output Generator Output (approx) 10° BTDC @ 1500 RPM NGK CR6E 0.7-0.8 mm (0.028-0.032 in.) 8000-12,000 ohms Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed to ground) 140.0-215.0 DC volts (blue/white to ground) 160-240 ohms (green to blue) Less than 1 ohm (black to black) Less than 1 ohm (yellow to white) 4.2-6.3 volts (green to blue) 0.4-0.6 volts (yellow to white) 60 AC volts @ 5000 RPM (black to black) 325W @ 5000 RPM H1 Models p/n Diagnostic Harness Spark Plug Cap 500 Ignition Timing Spark Plug Type Spark Plug Gap Spark Plug Cap Ignition Coil Resistance Ignition Timing Spark Plug Type Spark Plug Gap Spark Plug Cap Ignition Coil Resistance 10° BTDC @ 1500 RPM NGK CPR8E 0.7-0.8 mm (0.028-0.032 in.) 5000 ohms (primary) Less than 1 ohm (terminal (+) to terminal (-)) (secondary) 12k-19k ohms (high tension - plug cap to terminal (+)) Ignition Coil Primary Voltage Battery Voltage (orange (+) to blue/white(-)) Stator Coil Resistance (crankshaft position sensor) 150-250 ohms (blue to white) (AC generator) Less than 1 ohm (yellow to yellow) Crankshaft Position Sensor 5.0 volts or more (blue to green) AC Voltage AC Generator (no load) 75 AC volts @ 5000 RPM Output (yellow to yellow) H2 Models Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CPR8E (2) Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap Ignition Coil Resistance 5000 ohms (primary) 4.8 ohms (terminal (+) to terminal (-)) (secondary) 12k-19k ohms (high tension plug cap to terminal) Ignition Coil Primary Voltage Battery Voltage (orange to ground) Stator Coil Resistance (crankshaft position sensor) 150-250 ohms (blue to green) (AC generator) Less than 1 ohm (gray to gray) Ignition Coil (primary/CDI) 250-375 DC volts Peak Voltage (black/yellow to black) Crankshaft Position Sensor AC Voltage Stator Coil Resistance Generator Output (no load) 75 AC volts or more @ 5000 RPM (gray to gray) Peak Voltage AC Generator Output (trigger) 90-110 ohms (green to blue) (charging) Less than 1 ohm (black to black) (trigger) 7.8-9.3 volts (green to blue) (no load) 60 AC volts @ 3000 RPM (black to black) Generator Output (approx) 220W @ 5000 RPM www.mymowerparts.com 5-2 2.0 AC volts or more (blue to green) FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Battery After being in service, batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life. The following procedure is recommended for cleaning and maintaining batteries. Always read and follow instructions provided with battery chargers and battery products. 7. If the meter reads less than specified voltage, charge the battery using the following guidelines. A. When using an automatic battery charger, always follow the charger manufacturer’s instructions. B. When using a constant-current battery charger, use the following Battery Charging Chart. ! CAUTION Never exceed the standard charging rate. ! WARNING ! 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. An overheated battery could explode causing severe injury or death. Always monitor charging times and charge rates carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. 1. Remove the battery hold-down; then disconnect the battery cables (negative cable first). 2. Disconnect the vent hose (lead-acid battery). 3. Remove the battery from the battery compartment; then thoroughly wash the battery and battery compartment with soap and water. NOTE: If battery posts, cable ends, or the battery case has a build-up of white/green powder residue, apply water and baking soda to neutralize acid; then flush off with warm soapy water. 4. Using a wire brush, clean the battery posts and cable ends removing all corrosive buildup. Replace damaged cables or cable ends. 5. Add clean distilled water to bring fluid level to the UPPER level line (lead-acid battery). NOTE: The EFI models are equipped with a sealed battery. Do not attempt to add electrolyte to these batteries. ! WARNING Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. ! CAUTION Never use electrolyte (sulfuric acid) to “top off” the battery. Use only distilled water or severe battery damage may occur. 6. Using a multimeter, test the battery voltage. The meter must read 12.5 or more DC Volts for a fully charged battery. NOTE: At this point, if the meter reads as specified, the battery may be returned to service (see step 10). Battery Charging Chart (Constant-Current Charger) Battery Voltage (DC) Charge State Charge Time Required (at 1.5-2.0 Amps) 12.5 or more 100% None 12.2-12.4 75%-99% 3-6 hours 12.0-12.2 50%-74% 5-11 hours 11.0-11.9 25%-49% 13 hours (minimum) 11.5 or less 0-24% 20 hours (minimum) NOTE: If the battery voltage is 11.5 DC Volts or less, some chargers may “cut off” and fail to charge. If this occurs, connect a fully charged booster battery in parallel (positive to positive and negative to negative) for a short period of time with the charger connected. After 10-15 minutes, disconnect the booster battery leaving the charger connected and the charger should continue to charge. If the charger “cuts off,” replace the battery. 8. After charging the battery for the specified time, remove the battery charger and allow the battery to sit for 1-2 hours. 9. Connect the multimeter and test the battery voltage. The meter should read 12.5 or more DC Volts. If the voltage is as specified, the battery is ready for service. NOTE: If voltage in step 9 is below specifications, charge the battery an additional 1-5 hours; then retest. Recheck electrolyte level (lead-acid battery) and the battery is ready for service. 10. Place the battery in the battery compartment; then coat the battery posts and cable ends with a light coat of multi-purpose grease. ! CAUTION Before installing the battery, make sure the ignition switch is in the OFF position. www.mymowerparts.com 5-3 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Connect the battery cables (positive cable first); then install the battery hold-down. ! CAUTION Connecting cables in reverse (positive to negative and negative to positive) can cause serious damage to the electrical system. RPM Limiter NOTE: The ATV is equipped with a CDI unit/ECU that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire. Brakelight Switch (Auxiliary) 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. 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. Testing Electrical Components All of the electrical tests should be made using the Fluke Model 73 Multimeter and when testing peak voltage, the Peak Voltage Reading Adapter 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. AR627D 3. The meter must show battery voltage. NOTE: For absolute accuracy, all tests should be made at room temperature of 68° F. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, switch, or the main wiring harness. Accessory Receptacle/Connector 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. NOTE: This test procedure is for either the receptacle or the connector. VOLTAGE RESISTANCE (Switch Connector) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Turn the ignition switch to the ON position; then set the meter selector to the DC Voltage position. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the red/white wire or the positive connector; then connect the black tester lead to ground. 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire. 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. www.mymowerparts.com 5-4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. AR626D 3. When the brake pedal is depressed, the meter must show less than 1 ohm. 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire. 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. AR621D 3. When the lever is compressed, the meter must show less than 1 ohm. VOLTAGE (Wiring Harness Connector) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead 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. Oil Temperature and Cooling Fan Switches (400) 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 cooking oil; then heat the oil. 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: 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. ! WARNING Wear insulated gloves and safety glasses. Heated oil can cause severe burns. 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. www.mymowerparts.com 5-5 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 733-554C 733-554E 3. On the oil temperature switch when the oil temperature reaches 160° C (320° F), the meter should read a closed circuit. 3. On the coolant temperature switch when the oil temperature reaches 112-118° C (234-244° 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. 4. On the coolant temperature switch, allow the oil 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 120° C (248° F), the meter should read a closed circuit. 5. On the cooling fan switch when the temperature reaches 88° C (190° 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. 6. On the cooling fan switch, allow the oil to cool, and when the temperature is within a temperature range of 66° C (150° F), the meter should read an open circuit. 7. If the readings are not as indicated, the switch must be replaced. 7. If the readings are not as indicated, the switch must be replaced. 8. Apply thread tape to the threads of the switch; then install the switch and tighten securely. 8. Install the switch and tighten securely. 9. Connect the switch leads. Coolant Temperature and Cooling Fan Switches (500) 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 cooking 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. ! WARNING Wear insulated gloves and safety glasses. Heated oil can cause severe burns. www.mymowerparts.com 5-6 9. Connect the switch leads. Engine Coolant Temperature (ECT) Sensor (EFI Models) 1. Connect the meter leads (selector in OHMS position) to the sensor terminals. 2. Suspend the sensor and a thermometer in a container of cooking oil; then heat the oil. NOTE: Neither the 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 sensor and thermometer. ! WARNING Wear insulated gloves and safety glasses. Heated oil can cause severe burns. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. On the ECT sensor when the temperature reaches 20° C (68° F), the meter should read approximately 2.45k ohms. 4. On the ECT sensor when the temperature reaches 50° C (122° F), the meter should read approximately 800 ohms. 5. On the ECT sensor when the temperature reaches 80° C (176° F), the meter should read approximately 318 ohms. 6. On the ECT sensor when the temperature reaches 110° C (230° F), the meter should read approximately 142 ohms. 7. If the readings are not as indicated, the sensor must be replaced. 8. Install the sensor and tighten securely. 9. Connect the leads. 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) AR645D 3. 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. NOTE: To determine if the fan motor is good, connect the red wire from the fan connector to the positive side of a 12 volt DC power supply; then connect the black wire from the fan connector to the negative side. The fan should operate. ! WARNING Care should be taken to keep clear of the fan blades. 5 Power Distribution Module (PDM) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the black/red wire; 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. 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. NOTE: If the meter shows battery voltage, the main wiring harness is good. The connector should be checked for resistance. 2. Set the meter selector to the DC Voltage position. RESISTANCE (Fan Motor Connector) 4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. ! 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. www.mymowerparts.com 3. Connect the black tester lead to ground. 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. 5-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows no battery voltage, troubleshoot the battery, switches, distribution module, or the main wiring harness. 550/700 H1 Cruiser/H2 Cruiser FUSES NOTE: To remove a fuse, compress the locking tabs on either side of the fuse case and lift out. 400 1411-940 ! CAUTION Always replace a blown fuse with a fuse of the same type and rating. ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1411-963 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. 500 Auto 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. 0411-828 500 Manual RELAYS The relays are identical plug-in type. 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. 0411-837 Ignition Coil 550 H1 TRV/700 H1 EFI/Thundercat NOTE: On the H2 models, the following procedures should be performed on both ignition coils. The ignition coil is on the frame above the engine. To access the coil, the side panel must be removed (see Section 2). 1411-526 www.mymowerparts.com 5-8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. GZ389A 2. The meter reading must be within specification. Secondary Winding 1. Remove the plug cap from the high tension lead; then connect the red tester lead to the high tension lead. 2. On the H1/H2 models, connect the black tester lead to either primary connector; on the 400/500, connect the black tester lead to the coil frame or to the primary connector. 3. The meter reading must be within specification. KC329A NOTE: If the meter does not show as specified, replace ignition coil. 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. CD882B AR603D 2. The meter reading must be within specification. NOTE: If the meter does not read as specified, replace the spark plug cap. PEAK VOLTAGE CF234C www.mymowerparts.com NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter. If any other type of tester is used, readings may vary due to internal circuitry. 5-9 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The battery must be at full charge for these tests. Primary/CDI (400) NOTE: The CDI is located on the electrical tray in front of the steering shaft. NOTE: The ECU is located beneath the rear fender near the taillight. 1. Set the meter selector to the DC Voltage position; then disconnect the orange primary wire from the coil. 2. Connect the red tester lead to the orange primary wire; then connect the black tester lead to ground. 3. Turn the ignition switch to the ON position. 4. The meter reading must be within specification. EFI Sensors/ Components (EFI Models) KC210B 1. Set the meter selector to the DC Voltage position; then disconnect the black/yellow and black primary wires from the coil. 2. Connect the red tester lead to the black/yellow wire; then connect the black tester lead to the black wire. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. Primary/CDI (500) NOTE: The CDI 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. Primary Voltage - ECU (H1 Models) 1. Set the meter selector to the DC Voltage position; then disconnect the two wires from the coil. 2. Connect the red tester lead to the orange wire and the black tester lead to the blue/white wire. 3. Turn the ignition switch to the ON position. The meter must show battery voltage. Primary Voltage - ECU (H2 Models) NOTE: The battery must be at full charge for this test. www.mymowerparts.com 5-10 CRANKSHAFT POSITION (CKP) SENSOR To test the CKP sensor, see Stator Coil/Crankshaft Position (CKP) Sensor (EFI Models) in this section. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 1. Disconnect the MAP connector from the pressure sensor located on top of the throttle body. 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 orange/blue 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. 4. Connect the MAP to the harness; then using MaxiClips, 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 1.5 DC volts. NOTE: If the meter does not read as specified, replace the sensor. Speed Sensor NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor harness (manual transmission model) or on the speed sensor (automatic transmission models) for contamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 Ignition Switch CD884D The ignition switch harness connects to the switch with a four-pin connector. To access the connector, remove the ignition switch nut, remove the switch, and press the connector release tab. Pull the connector from the switch. 5 CD885D 3. Turn the ignition switch to the ON position. 4. The meter must show 6-12 DC volts. 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead (S) pin. CF272A 6. Slowly move the ATV forward or backward; the meter must show 0 and 6-12 DC volts alternately. 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. 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. www.mymowerparts.com CF273A VOLTAGE NOTE: Perform this test on the harness connector. 1. Set the meter selector to the DC Voltage position. 2. Connect the red meter lead to either red wire; then connect the black meter lead to ground. 5-11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 switch using the following procedure. Handlebar Control Switches 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. 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. With the dimmer switch in the HI position, the meter must show less than 1 ohm. CF274A 1. Turn the ignition switch to the ON position. 2. Set the meter selector to the OHMS position. 3. Connect either tester lead to pin C; then connect the other tester lead to pin D. 4. The meter must show less than 1 ohm. 5. Turn the ignition switch to the LIGHTS position. 6. Connect either tester lead to pin A; then connect the other tester lead to pin B. 7. The meter must show less than 1 ohm. 8. Connect either tester lead to pin C; then connect the other tester lead to pin D. 9. The meter must show less than 1 ohm. 10. With the switch in the OFF position, connect the red tester lead and the black tester lead to each of the remaining pins. The meter must show an open circuit on all pins. NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot or replace the switch/ component or the connector. 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. 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. www.mymowerparts.com 5-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Connect the red tester lead to the yellow/green wire; then connect the black tester lead to the orange/white wire. 6. With the starter button depressed, the meter must show 0 DC volts. Front Drive Selector Switch NOTE: If the meter does not show as specified, replace the switch/component, connector, or switch harness. 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. RESISTANCE (Emergency Stop) NOTE: Resistance tests should be made with the connector disconnected and on the selector-side of the connector. 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. RESISTANCE 3. With the switch in the OFF position, the meter must show an open circuit. Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 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. 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. ! CAUTION 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 (400/500) or open circuit (H1/H2 models). 4. With the selector switch in the 4WD position, the meter must show an open circuit (400/500) or less than 1 ohm (H1/H2 models). 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. 2. Connect the black tester lead to the negative battery terminal. 3. Connect the red tester lead to the red (400/500) or white (H1/H2 models) 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. www.mymowerparts.com 5-13 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Drive Selector Actuator Front Drive/Differential Lock Actuator 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: 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. NOTE: The differential must be in the unlocked position for this procedure. VOLTAGE VOLTAGE (400/500) (H1/H2 Models) 1. Select the 2WD position on the front drive selector switch; then disconnect the connector on the actuator wiring harness. 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. 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. 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. 4. Connect the red tester lead to the white/orange 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. 5. Connect the red tester lead to the white/green wire in the supply harness. The meter must show 10.2 DC volts. NOTE: The 4WD icon on the LCD should illuminate. 6. Select the 4WD position on the front drive selector switch; then connect the red tester lead to the white/orange wire in the supply harness. The meter must show 12 DC volts. 6. Connect the red tester lead to the orange wire in the supply harness. The meter must show 12 DC volts. NOTE: The 4WD icon on the LCD should illuminate. NOTE: If the voltage readings are as specified and the actuator does not function correctly, replace the actuator (see Section 6). 7. Connect the red tester lead to the white/green wire in the supply harness. The meter must show 0 DC volts. 8. Select Differential Lock on the front drive actuator switch; then connect the red tester lead to the white/orange wire in the supply harness. The meter must show 0 DC volts. 9. Connect the tester lead to the white/green wire in the supply harness. The meter must show 0 DC volts. NOTE: The 4WD and LOCK icons on the LCD should illuminate. www.mymowerparts.com 5-14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the voltage readings are as specified and the actuator does not function correctly, replace the actuator (see Section 6). Differential Lock Switch (500) VOLTAGE CF094C 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. 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. Differential Lock Control Switch (H1/H2 Models) RESISTANCE Disconnect the switch from the main harness; then with the tester set to the OHMS position, test the switch as follows. 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. “Unlocked” Position “Locked” Position A to B A to C B to C A to B A to C B to C <1 Ohm 50 Ohms <1 Ohm <1 Ohm 50 Ohms 50 Ohms Stator Coil (400/500) VOLTAGE (AC Generator - 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. www.mymowerparts.com CD576 NOTE: If voltage is lower than specified, test charging coil - no load. 5-15 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Charging Coil - No Load) The connector is a three-pin one in the harness coming from the AC generator. NOTE: Test the engine-side of the connector. 1. Set the meter selector to the AC Voltage position. 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. Trigger Coil 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. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. Stator Coil/Crankshaft Position (CKP) Sensor (EFI Models) ! 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. RESISTANCE (Charging Coil) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to OHMS position. VOLTAGE (AC Generator - 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 2. Test between the three black wires for a total of three tests. Do not run the engine at high RPM for more than 10 seconds. 3. The meter reading must be within specification. NOTE: If voltage is lower than specified, test AC Generator - No Load. RESISTANCE (Trigger Coil) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. VOLTAGE (AC Generator - No Load) The connector is a three-pin one in the harness coming from the generator. 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. PEAK VOLTAGE NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter. 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 5-16 FI083B NOTE: Test the connector that comes from the engine. 1. Set the meter selector to the AC Voltage position. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Test between the three yellow wires (H1 models) or gray wires (H2 models) for a total of three tests. 3. With the engine running at a constant 5000 RPM, all wire tests must be within specifications. ! 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. Starter Relay 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. RESISTANCE (AC Generator) ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to OHMS position. 2. Test between the three yellow wires (H1 models) or gray wires (H2 models) 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 (H1 models) or green wire (H2 models). The meter reading must be within specification. AC VOLTAGE NOTE: The battery must be at full charge for these tests. Crankshaft Position Sensor 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. 1. Set the meter selector to the AC Voltage position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the green wire. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification. KX059A www.mymowerparts.com 5. Depress the starter button and observe the multimeter. 5-17 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If battery voltage is indicated, replace the starter relay. If no voltage is indicated, proceed to Power Distribution Module (PDM) check. REMOVING/DISASSEMBLING 1. Disconnect the battery. ! CAUTION Starter Motor Always disconnect the negative battery cable from the battery first; then disconnect the positive cable. NOTE: On the 400/H1/H2 models, the starter is a non-serviceable component. If the following test does not result as specified, the starter must be replaced. TESTING VOLTAGE 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. AT THIS POINT Perform this test on the starter motor positive terminal. To access the terminal, slide the boot away. 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. On the 400/H1/H2 models to install the starter, proceed to ASSEMBLING/INSTALLING - steps 10-12 in this sub-section. 4. For assembly purposes, scribe a line across the outside of the starter assembly. 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. 3. With the starter button depressed, the meter must show approximately 10.0 DC volts and the starter motor should operate. 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. AR607D NOTE: If the meter showed correct voltage but the starter did not operate or operated slowly, the starter motor is defective. NOTE: If the meter showed no voltage, inspect the main fuse, ground connections, starter motor lead, battery voltage (at the battery), starter relay, or the neutral start relay. BC003 7. Remove the rear cover. 8. Slide the armature free of the starter housing. www.mymowerparts.com 5-18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the positive brush assembly from the starter housing. BC006 9. Bend the two positive brushes outward; then remove the brush holder. BC009 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 BC007 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. BC010 10. Remove the nut from the positive post. Account for the lock washer, flat washer, a fiber washer, and an O-ring. 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. BC008 www.mymowerparts.com 5-19 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.). 12. Inspect the ground brushes to make sure they are properly grounded. Use a multimeter and the following procedure. A. Set the selector to the OHMS position. 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. 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. 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. 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. BC008 3. Align the tab on the brush holder with the notch in the starter housing; then install. www.mymowerparts.com 5-20 0725-653 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 BC010 BC014 4. Install the armature into the starter housing; then while holding the brushes out, slide the commutator into the brush holder. 7. Apply a small amount of grease to the front cover bearing and seal; then install the seal protector. BC015 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. BC004 8. Place the front cover onto the starter housing making sure it seats properly. 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. 9. Apply red Loctite #271 to the threads of the two long cap screws and install. Tighten to 8 ft-lb. www.mymowerparts.com 5-21 5 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 (EFI models) sub-section in this section. Regulator/Rectifier The regulator/rectifier is located under the rear rack and rear fenders. TESTING AR653D 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. CDI Unit (400/500) 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. 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 in this section. If charging coil voltage is normal, replace the regulator/rectifier. 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. 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 Coil 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) (EFI Models) Headlights The connectors are the four 2-prong ones secured to the front bumper supports (two on each side) with cable ties. 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. The electronic control unit (ECU) is located beneath the seat near the battery (H1 models) or under the fender near the taillight (H2 models). 2. Connect the red tester lead to one wire; then connect the black tester lead to the other wire. NOTE: The ECU is not a serviceable component. If the unit is defective, it must be replaced. 3. With the dimmer switch in the LO position, test the two outside connectors (LO beam). The meter must show battery voltage. 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. 4. With the dimmer switch in the HI position, test the two inside connectors (HI beam). The meter must show battery voltage. www.mymowerparts.com 5-22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If battery voltage is not shown in any test, inspect the LIGHTS fuse, 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. 1. Attach the Timing Light to the spark plug high tension lead; then remove the timing inspection plug from the left-side crankcase cover. 2. Using the Tachometer, start the engine and run at 1500 RPM; ignition timing should be 10° BTDC. 3. Install the timing inspection plug. 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. 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. ECU Error Codes (EFI Models) 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 (if equipped) or the LCD gauge going blank (if equipped). The EFI icon will flash. To read the error code(s), use the following procedure. 1. Make sure the ignition switch is in the OFF position; then remove the seat. 2. Locate the diagnostic plug next to the PDM; then remove the black rubber cap. 3. Connect the Diagnostic Harness 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. Ignition Timing The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components. To verify ignition timing, use the following procedure. 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. ECU Error Code List NOTE: Each of the following numerical codes will have a two-letter prefix. A prefix of AC (Active Code) or SC (Stored Code) will be displayed. Always correct and clear Active Codes before clearing Stored Codes. www.mymowerparts.com 5-23 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 • • • • • • • • • • • • • • • • • • • • • 00 = 12 = 13 = 13 = 14 = 15 = 16 = 21 = 23 = 24 = 26 = 32 = 34 = 40 = 41 = 60 = 95 = 96 = 97 = 98 = 99 = No Fault Detected (active code only) CKP (Crankshaft Position) Sensor* APS (Air Pressure Sensor) - H1 MAP (Manifold Absolute Pressure) Sensor - H2 TPS (Throttle Position Sensor) ECT (Engine Coolant Temperature) Sensor Speed Sensor IAT (Inlet Air Temperature) Sensor Tilt Sensor* Ignition Coil #1* Ignition Coil #2* - H2 Fuel Injector #1* Fuel Injector #2* - H2 ISC (Idle Speed Control) Valve Fuel Pump Relay* Cooling Fan Relay Sensor Power Incorrect ECU* ECU Memory Power (constant battery power) UART Comm Link - H2 Start/Run Not Possible (active code only) *Will initiate code 99. To clear the error code(s), use the following procedure. NOTE: The ignition switch should be in the OFF position. 1. With the diagnostic harness connected to the diagnostic plug and the drive select switch in the 4WD position, hold the reverse override switch down and turn the ignition switch to the ON position. SUPPLY VOLTAGE 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). 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 ECU or substitute another ECU to verify the test. 2. After ten seconds, release the reverse override switch and turn the ignition switch to the OFF position; then turn the ignition switch to the ON position. The display should read AC00 (no fault detected). NOTE: If the LCD still displays an error code, continue troubleshooting the appropriate component. 3. Disconnect the diagnostic harness; then install the black rubber cap. 4. Install the seat making sure it locks securely in place. CD706B OUTPUT VOLTAGE Tilt Sensor (EFI Models) NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected. ! WARNING 1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the rear frame. 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. www.mymowerparts.com 5-24 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) (EFI Models) INSPECTING 1. Remove the left-side engine cover; then disconnect the three-wire TPS connector plug. 5 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. PR544 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 terminal C and the red tester lead to terminal B. Turn the ignition switch to the ON position. The meter should read approximately 5.0 DC volts. CD709 NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up. www.mymowerparts.com 5-25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Connect the positive lead to the battery; then connect the negative lead. 8. Connect the main harness TPS connector to the TPS; then using MaxiClips, connect the black tester lead to the black/green wire and the red tester lead to the green/black wire. PR538A 4. Remove the red tester lead from terminal B and connect it to terminal A. The meter should read 0 DC volts. NOTE: If the meter does not read as specified, check for poor connections at the ECU or open/broken wires in the wiring harness. ! CAUTION 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). ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. PR546A 9. Select the DC Voltage position on the meter and turn the ignition switch to the ON position. The meter should read approximately 0.60 DC volt with the throttle closed and approximately 4.0 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). 6. Select the OHMS position on the meter; then perform the following resistance tests on the TPS. ! CAUTION Always make sure the ignition switch is in the OFF position before disconnecting the ECU. 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. 10. Clear all ECU error codes after servicing is complete (see ECU Error Codes (EFI Models) in this section). REMOVING 1. Remove the left-side engine cover; then disconnect the three-wire TPS connector plug. PR535A NOTE: If any meter reading is not as specified, replace or adjust the TPS (see INSTALLING/ADJUSTING in this sub-section). www.mymowerparts.com 5-26 PR544 2. Remove the two screws securing the TPS to the throttle body and remove the TPS. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 next to the PDM; then install the test plug from Test Plug/Error Code List kit onto the connector. 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). PR540A PR541A PR542A 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 5-27 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting 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 (400/500) Idling RPM too high (400/500) 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 (400/500) 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 www.mymowerparts.com 5-28 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 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 (500) 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. 2. 3. 4. 5. 6. Electrolyte contaminated Specific gravity too low Charging system not charging Cell plates overcharged - damaged Battery short-circuited Specific gravity too low Problem: Battery polarity reversed Condition 1. Battery incorrectly connected 1. 2. 3. 4. 5. Replace battery Keep electrolyte to prescribed level Charge battery - add distilled water Replace battery Replace battery Remedy 1. 2. 3. 4. 5. 6. Replace battery Charge battery - add distilled water Check magneto - regulator/rectifier - circuit connections Replace battery - correct charging system Replace battery Charge battery Remedy 1. Reverse connections - replace battery - repair damage www.mymowerparts.com 5-29 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM 6 TABLE OF CONTENTS Drive System ........................................................... 6-2 Front Drive Actuator (400/500)/Electronic Differential Lock (H1/H2 Models) ......................... 6-2 Front Differential ...................................................... 6-3 Drive Axles ............................................................ 6-17 Rear Gear Case .................................................... 6-21 Hub........................................................................ 6-23 Hydraulic Brake Caliper......................................... 6-25 Troubleshooting Drive System............................... 6-26 Troubleshooting Brake System.............................. 6-27 www.mymowerparts.com 6-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Special tools are available from the Arctic Cat Service Parts Department. 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 1. NOTE: 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.) GENERAL INFORMATION 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). Front Drive Actuator (400/500)/Electronic Differential Lock (H1/H2 Models) 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 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 (400/500) or the electronic differential lock is activated (H1/H2 models). If no sound is heard, see Section 5. If the actuator runs constantly or makes squealing or grinding sounds, the actuator must be replaced. REMOVING B. A “1” or “3.1” on the lower-right corner indicates a 3.1:1 gear set ratio (11:34 teeth). 1. Disconnect the connector on the actuator harness. C. A “4.0” on the lower-right corner indicates a 4.0:1 gear set ratio (9:36 teeth). 2. Using a T-30 torx wrench, remove the mounting cap screw from the driveshaft side of the actuator. 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) 8-9.5 ft-lb 6.5-9 ft-lb M8 (Torx T-40 Recess) 25-31 ft-lb 21-25 ft-lb M10 (Torx T-50 Recess) 37-45.5 ft-lb 31-38 ft-lb SPECIAL TOOLS AG926 A number of special tools must be available to the technician when performing service procedures in this section. Description p/n CV Boot Clamp Tool 0444-120 CV Boot Clamp Tool 0444-250 Internal Hex Socket 0444-104 Pinion Gear/Shaft Removal Tool 0444-127 Slide Hammer Kit 0444-225 Seal Installation Tool 0444-224 www.mymowerparts.com 6-2 3. Remove the mounting cap screw from below the actuator on the suspension side. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 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. AG928 4. Loosen the front cap screw; then tighten the cap screw on the driveshaft side. AG928 INSTALLING AG926 NOTE: On the H1/H2 models, make sure to properly align the differential lock actuator lever with the hole in the differential lock plunger. NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator. 1. Lubricate the O-rings on the actuator; then ensure that all mounting surfaces are clean and free of debris. 5. Tighten the remaining cap screws; then connect the electrical plug to the main harness. 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. 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. Front Differential NOTE: To remove the rear gear case, see Rear Gear Case in this section. AG925 www.mymowerparts.com 6-3 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING DIFFERENTIAL 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. Remove the drain plug and drain the gear lubricant into a drain pan; then reinstall the plug and tighten to 45 in.-lb. AF894D 8. Remove the tie rod cotter pins and discard the pins. ATV0082A 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. AF895D 9. Remove the tie rod lock nuts. AF896D KX041 6. Release the brake lever lock. NOTE: It is not necessary to remove the brake hoses from the calipers for this procedure. 7. Remove the two brake calipers. Account for the four cap screws. www.mymowerparts.com 6-4 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF628D 11. Pull the steering knuckle away from the axle. AF610D 15. Using a slide hammer, remove the front axles. KX151 12. Support the axle to not allow it to drop or hang. ! CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. AF899D 16. Remove the inner fender panels. 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case; then remove the actuator. 13. Remove the lower shock bolts. Account for the lock nuts; then move the shocks aside and secure them with a strap. AG925 18. Remove the lower differential mounting cap screw. Account for a lock nut and washers. AF897D 14. Remove the upper A-arm lock nuts and cap screws; then remove the A-arms. www.mymowerparts.com 6-5 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD026 19. Remove the upper differential mounting cap screws. 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. 1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing. CD016 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. 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. KX161 21. Place the differential on its right side; then remove it from the frame. CD103 www.mymowerparts.com 6-6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD106 AF983 3. Using a boot-clamp pliers (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing. AF984 CD107 5. Using a seal removal tool, remove the input shaft seal. Account for a spacer. 6 KX219 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. www.mymowerparts.com AF993 6-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF994 CD112 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 #2 Molybdenum Disulphide Grease. NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air; then lubricate with recommended grease. CD099 5. Place the pinion housing with new gasket onto the gear case housing; then secure with the existing cap screws. Tighten to 23 ft-lb. NOTE: If a new gear case housing is being installed, tighten the cap screws to 25-31 ft-lb. KX221 CD103 Disassembling Pinion Gear KX222 4. Install the input shaft into the pinion housing; then install the front boot and secure with an appropriate boot clamp and the rear boot with an appropriate boot clamp. www.mymowerparts.com 6-8 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX209 KX175 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. 5. Remove the left gear case bearing flange assembly and account for a shim. Mark the shim as left-side. KX177 KX173 3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring. 6 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. KX174 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. KX179 www.mymowerparts.com 6-9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX181 CC878 7. Using the 48 mm Internal Hex Socket, remove the lock collar securing the pinion gear assembly. 9. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press. Account for a collar and a bearing. 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 and a hammer, remove the pinion gear from the gear case housing. www.mymowerparts.com 6-10 1. Press bearings into bores by outer ring to contact with seat. 2. Install the lock collar and tighten to 125 ft-lb; then on final assembling, stake the lock collar edge approximately 1.5 mm into the lower oil channel. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC891 CC882 3. Note the following shim selections (shims are nominally 1.5 mm thick): CC883 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. 738-268C A. Cover Side - add value A on the gear case housing to value B on the gear case cover; then add 1.5 mm. This will give you the proper shim thickness. 6 NOTE: When shimming a rear gear case, add value A to value B. B. Gear Case Side - install a 1.3-1.4 mm shim and tighten the bolts to 28 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, secure the pinion gear assembly with the existing lock collar. Tighten to 125 ft-lb. 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. www.mymowerparts.com 6-11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC890 CC893 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. 7. Place the pinion housing assembly onto the gear housing; then secure with the existing cap screws. Tighten to 23 ft-lb. NOTE: If a new gear housing is being installed, tighten the cap screws to 25-31 ft-lb. CC891 5. Install the shift fork shaft w/spring into the gear housing making sure the shaft O-ring is positioned to the inside. CD103 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. www.mymowerparts.com 6-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Apply a liberal amount of grease to the O-ring; then install it on the assembled cover assembly making sure to seat the O-ring down around the circumference of the bearing flange. 11. Making sure the O-ring is properly positioned on the differential/gear case cover assembly, install the cover with existing hardware. Account for the ID tag. Tighten the cap screws (coated with green Loctite #609) to 23 ft-lb. NOTE: Grease can be applied to the O-ring for ease of assembling. CC896 NOTE: If a new gear case housing is being installed, tighten the cap screws to 25-31 ft-lb. 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. CC897 9. Assemble the fork and sliding collar into the cover assembly; then install left bearing flange/bearing assembly and seat it firmly into the cover. 1. Place a 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. 6 CC885 CF266A CF267A 2. Using a propane torch, heat the area surrounding the needle bearing to soften the Loctite. CC886 3. Using a flat-nosed punch, drive the bearing out of the housing. www.mymowerparts.com 6-13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC887 Installing Needle Bearing 1. Apply red Loctite #271 to the outside of a new bearing; then place the new bearing into the housing. 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. 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. CC889 3. Install the pinion shaft and secure with the existing 48 mm lock collar. Tighten to 125 ft-lb. www.mymowerparts.com 6-14 CC899 2. Using a press, remove the bearing. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 38 ft-lb. 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 High Performance #2 Molybdenum Disulphide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated. ! CAUTION Make sure the tool is free of nicks or sharp edges or the seal will be damaged. CD859 2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid gear lubricant into the differential and install the filler plug. Tighten to 16 ft-lb. 3. Install the front drive actuator with the three torx-head cap screws; then connect the wire connector to the main wiring harness. CF278 5. Repeat steps 1-4 for the opposite side. AG925 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this section). www.mymowerparts.com 6-15 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Secure the upper A-arms with cap screws and lock nuts. Tighten to 35 ft-lb. AF895D AF610D 9. Install the brake calipers and secure with the patch-lock cap screws tightened to 20 ft-lb. 7. Secure the lower shock eyelets with cap screws and lock nuts. Tighten to 35 ft-lb (400/500/H1 models) or to 50 ft-lb (H2 models). AF894D 10. Install the wheels and tighten to 40 ft-lb. 11. Remove the ATV from the support stand. AF897D 8. Secure the tie rods with the lock nuts. Tighten to 30 ft-lb; then install and spread the cotter pins. Drive Axles 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. AF896D 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. www.mymowerparts.com 6-16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 8. While holding the drive axle stationary, pull the top of the knuckle out and down until it is free of the drive axle. 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. DISASSEMBLING AXLES 1. Using a side-cutters (or suitable substitute), remove the large clamp from the boot. 9. Place a drain pan under the ATV to contain any oil leakage; then using a slide hammer, remove the drive axle. CD020 2. Wipe away excess grease to access the retaining ring. Using an awl, remove the circlip. AF935 REMOVING FRONT DRIVE AXLE NOTE: For removing a front drive axle, see Front Differential in this section. www.mymowerparts.com 6-17 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD021 CD752 3. Using a snap ring pliers, remove the snap ring securing the bearing ring to the shaft. Note the direction of the bearing for assembling purposes. 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 8. Apply 40 grams (1/3 of contents) of grease from the Grease Pack into the knuckles and the new outside boot. CD022 5. Inspect the splines of the shaft, the bearing ring, and the housing for damage. 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. www.mymowerparts.com 6-18 ATV-1052 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Grease Pack 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. 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 ATV-1048 10. Using the CV Boot Clamp Tool, secure both outside boot clamps. 3. Apply 80 grams (2/3 of contents) of grease from the pack into the bearing housing. ! CAUTION 4. Install the bearing onto the shaft making sure the recess of the bearing is facing the housing. It is important that the clamps are positioned correctly or they may loosen when in motion. CD022 CD024 ASSEMBLING AXLES 1. Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly. ! 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 snap ring making sure the sharp side of the snap ring faces away from the boot. www.mymowerparts.com 6-19 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 35 ft-lb (400/500/H1 models) or to 50 ft-lb (H2 models). 3. Place the hub into position on the axle followed by a hex nut. Tighten the hex nut finger-tight at this time. 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. 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 20 ft-lb. Tighten the hydraulic brake caliper cap screws to 20 ft-lb. 5. Pump up the hand brake lever; then engage the brake lever lock. 6. Tighten the hub hex nut (from step 3) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut. CD021 7. Slide the boot over the housing; then using the boot clamp pliers, secure the boot with the clamp. CD027 7. Install the wheel. Tighten to 40 ft-lb. 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 35 ft-lb. 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. www.mymowerparts.com 6-20 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 35 ft-lb. 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. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the brake caliper on the steering knuckle. Tighten to 20 ft-lb; then pump up the hand brake lever and engage the brake lever lock. 6. Tighten the hub hex nut (from step 4) to 200 ft-lb; 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 40 ft-lb. 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. AF960A AT THIS POINT For servicing the input shaft (500/H1 models), pinion gear, needle bearing, and axle seal, see Front Differential in this section. REAR DRIVE INPUT SHAFT/ HOUSING (H2 Models) Removing/Disassembling CF113A Rear Gear Case 1. Remove the cap screws securing the rear drive input shaft/housing to the rear gear case; then remove the input housing assembly. 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. GZ183 www.mymowerparts.com 6-21 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the clutch pack from the clutch basket; then remove the snap ring securing the clutch basket (A) to the input shaft (B) and remove the clutch basket. GZ182A 4. Remove the snap ring retaining the input bearing and using an appropriate bearing driver, press the bearing from the housing. GZ392 GZ184A GZ176A Cleaning and Inspecting 1. Wash all parts in parts cleaning solvent and dry with compressed air. ! WARNING Always wear safety glasses when working with compressed air. 2. Clean all gasket material and sealant from mating surfaces. GZ177 3. Remove the input shaft from the input housing; then remove the oil seal. www.mymowerparts.com 6-22 GZ180 3. Inspect bearings, shafts, and housing for excessive wear, cracks, or discoloration. 4. Inspect the clutch basket for wear in splines or cracks in the housing. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ178A 5. Inspect the clutch pack for signs of discoloration. NOTE: The clutch pack is not a serviceable component. If worn, discolored, or damaged in any way, it must be replaced. GZ179A 4. Install the clutch basket onto the input shaft and secure with the snap ring (flat side directed outward); then install the clutch pack into the basket. Assembling/Installing 1. Install a new bearing into the input housing and secure with the snap ring (flat side directed away from bearing). GZ176 5. Using a new gasket, install the assembled rear drive input shaft/housing onto the rear drive gear case and secure with the three cap screws. Tighten to 23 ft-lb. INSTALLING GZ184 2. Using a suitable seal driver, install a new oil seal into the front of the input housing until the seal flush with the housing. 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 45 ft-lb. 2. Secure the engine output shaft to the rear gear case input flange with four cap screws (coated with red Loctite #271) and lock nuts. Tighten to 20 ft-lb. 3. Install the rear drive axles (see Drive Axles in this section). 4. Install the left-side rear A-arms (see Rear A-Arms in Section 7). Hub GZ182A 3. Apply grease to the lips of the oil seal; then install the input shaft into the input bearing and housing. REMOVING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. www.mymowerparts.com 6-23 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the cotter pin from the nut. NOTE: During assembly, new cotter pins should be installed. 1. Secure the brake disc to the hub with the four cap screws coated with blue Loctite #243. Tighten to 15 ft-lb. 2. Apply grease to the splines in the hub. 3. Install the hub assembly onto the shaft. KX041 3. Remove the flange nut securing the hub. PR290 4. Secure the hub assembly with the nut. Tighten only until snug. 4. Remove the brake caliper. 5. Secure the brake caliper to the knuckle with the two cap screws. Tighten the auxiliary caliper to 20 ft-lb. Tighten the hydraulic caliper to 20 ft-lb. PR243A 5. Remove the hub assembly. 6. Remove the four cap screws securing the brake disc. CLEANING AND INSPECTING PR243A 6. Tighten the hub nut (from step 4) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 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. PR260 7. Install the wheel and tighten to 40 ft-lb. www.mymowerparts.com 6-24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the ATV from the support stand. Hydraulic Brake Caliper NOTE: The brake calliper is a non-serviceable component; it must be replaced as an assembly. REMOVING/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. PR238 5. Remove the caliper holder from the caliper and account for the brake caliper O-ring. Do not remove the piston from the caliper. 2. Drain the brake fluid from the caliper, hose, and master cylinder. PR239B 6. Plug the fluid port with a suitable plug to prevent contamination during cleaning. PR235 ! CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV and do not reuse brake fluid. 3. Remove the brake hose from the caliper; then remove the caliper and plug the brake fluid port. 4. Compress the caliper holder against the caliper and remove the outer brake pad; then remove the inner brake pad. PR240A CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with parts-cleaning solvent. 2. Inspect the brake pads for damage and excessive wear. NOTE: For measuring brake pads, see Section 2. ASSEMBLING/INSTALLING PR237 www.mymowerparts.com 1. Install the caliper onto the caliper holder making sure the caliper is correctly oriented on the holder. 6-25 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR239C PR239 2. Compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. 3. Place the brake caliper assembly into position and secure with the cap screws. Tighten the caliper to 20 ft-lb. 4. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb. 5. Fill the reservoir; then bleed the brake system (see Section 2). 6. Install the wheel. Tighten to 40 ft-lb. 7. Remove the ATV from the support stand and verify brake operation. PR238 Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition 1. Secondary drive - driven gear teeth broken 2. Propeller shaft serration worn - broken 3. Coupling damaged 4. Coupling joint serration worn - damaged 5. Front drive - driven bevel gears broken - damaged 6. Front differential gears/pinions broken - damaged 7. Sliding dogs/shaft fork worn - damaged 8. Front drive axle worn - damaged 9. Front drive axle serration worn - damaged www.mymowerparts.com 6-26 Remedy 1. Replace gear(s) 2. Replace shaft 3. Replace coupling 4. Replace joint 5. Replace gear(s) 6. Replace gears - pinions 7. Replace gear(s) 8. Replace axle 9. Replace axle FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Brake System 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 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 6 www.mymowerparts.com 6-27 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 Troubleshooting ....................................................... 7-8 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 1. 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 using a pressure washer. 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. 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. 2. Place bushings and sleeves (where appropriate) into shock eyelet; then install shock with two cap screws and nuts. Tighten all front suspension nuts to 35 ft-lb. Tighten rear suspension nuts (upper) to 35 ft-lb (400/500/H1 models); tighten rear suspension nuts (upper) to 50 ft-lb (H2 models). www.mymowerparts.com 7-2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Do not tighten the nuts beyond the recommended specification or the shock eyelet or mount WILL be damaged. 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. NOTE: The rear shock absorber-to-lower A-arm torque factor is 20 ft-lb. 3. Remove the ATV from the support stand. Front A-Arms REMOVING AF618D 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. 7. Remove the cap screws securing the ball joints to the knuckle. ! WARNING ! CAUTION Make sure the ATV is solidly supported on the support stand to avoid injury. Support the knuckle when removing the cap screws or damage to the threads will occur. 2. Remove the cotter pin from the nut. Discard the cotter pin. AF628D CD008 3. Remove the nut securing the hub. 4. Remove the brake caliper. Account for two cap screws. 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. 10. Remove the cap screws securing the A-arms to the frame. CD007 5. Remove the hub assembly. www.mymowerparts.com AF610D 11. Remove the circlip from the ball joint; then remove the ball joint from the A-arm. 7-3 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF616D CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. AF610D 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. 1. Clean all A-arm components using a pressure washer. 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. DE054A 5. Inspect the frame mounts for signs of damage, wear, or weldment damage. 4. Secure the lower eyelet of the shock absorber to the upper A-arm. Tighten nut to 35 ft-lb. 5. Secure the A-arm assemblies to the frame mounts (from step 2). Tighten the cap screws to 35 ft-lb. 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 snap ring. ! CAUTION Do not tighten the nut beyond the 35 ft-lb specification or the shock eyelet or mount WILL be damaged. 6. Install the knuckle assembly onto the ball joints and secure with cap screws. Tighten to 35 ft-lb. AF616D 2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten at this time. AF628D 7. Install the tie rod end and secure with the nut. Tighten to 30 ft-lb; then install a new cotter pin and spread the pin to secure the nut. www.mymowerparts.com 7-4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: During assembly, new cotter pins should be installed. CD008 13. Install the wheel and tighten to 40 ft-lb. AF618D 8. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. 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 Make sure the ATV is solidly supported on the support stand to avoid injury. CD009 9. Secure the hub assembly with the nut. Tighten only until snug. 10. Secure the brake caliper to the knuckle with the two Patch-lock cap screws. Tighten to 20 ft-lb. 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. 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. CD007 11. Secure the hub nut (from step 9) to the shaft/axle. Tighten to 200 ft-lb. 12. Install a new cotter pin and spread the pin to secure the nut. www.mymowerparts.com 7-5 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF934 8. Slide the hub out of the knuckle and set aside. 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. PR290 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 20 ft-lb. NOTE: Ensure that the brake hose is properly routed and secured to the upper A-arm. 10. Remove the cap screws and lock nuts securing the A-arms to the frame; then remove the A-arms. 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 using a pressure washer. DE054A 2. Inspect the A-arm for bends, cracks, and worn bushings. 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 200 ft-lb. 3. Inspect the frame mounts for signs of damage, wear, or weldment damage. 8. Install a new cotter pin and spread the pin to secure the nut. 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 35 ft-lb (400/500/H1 models) or to 50 ft-lb (H2 models). 3. Tighten the hardware securing the A-arms to the frame mounts (from step 1) to 35 ft-lb (400/500/H1 models) or to 50 ft-lb (H2 models). 4. Apply grease on the drive axle splines; then install the hub assembly onto the drive axle. www.mymowerparts.com 7-6 PR260 9. Secure the shock absorber to the frame with a cap screw and new lock nut. Tighten to 35 ft-lb (400/500/H1 models) or to 50 ft-lb (H2 models). FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Secure the shock absorber to the lower A-arm with a cap screw and new lock nut. Tighten to 20 ft-lb. 11. Secure the boot guard to the lower A-arm with the two cap screws. Tighten securely. 12. Install the wheel and tighten to 40 ft-lb. 2. Remove the wheels. NOTE: Keep left-side and right-side wheels separated for installing them on their proper sides. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 13. Remove the ATV from the support stand. Wheels and Tires 1. Clean the wheels and hubs using a pressure washer. 2. Inspect each wheel for cracks, dents, or bends. KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 3. Inspect each tire for cuts, wear, missing lugs, and leaks. Shoulder Screw Brake Disc Wheel Hub - Front Hub Stud Wheel Hub - Rear Hex Nut Cotter Pin Wheel Mounting Nut Tire Valve Stem Valve Stem Cap INSTALLING Install each wheel on its hub. Tighten to 40 ft-lb. 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). 0741-559 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 Section 1. Do not under any circumstances substitute tires of a different type or size. ! WARNING 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 7 AF612D 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. 2. Inspect the tires for damage, wear, or punctures. ! WARNING Do not operate the ATV if tire damage exists. NOTE: Be sure all tires are the specified size and have identical tread pattern. 1. Secure the ATV on a support stand to elevate the wheels. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Section 8). ! WARNING 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, deceleration, and braking. Make sure the ATV is solidly supported on the support stand to avoid injury. www.mymowerparts.com 7-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Increase the air pressure in the tires with the smallest circumference measurement until all tires are equal in circumference. 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). 6. Repeat steps 4-5 as necessary to ensure proper handling. Troubleshooting 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 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 www.mymowerparts.com 7-8 Remedy 1. Replace spring(s) 2. Replace shock absorber 3. Adjust shock absorber preload Remedy 1. Replace bushing 2. Adjust shock absorber preload Remedy 1. Tighten cap screws 2. Replace bushings 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS 8 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 .......................................... 8-9 Front Body Panel/Side Panels............................... 8-10 Footrests ............................................................... 8-13 Belly Panel ............................................................ 8-14 Exhaust System .................................................... 8-14 Rear Body Panel/Rack .......................................... 8-14 Taillight Assembly.................................................. 8-15 Seat ....................................................................... 8-16 Troubleshooting ..................................................... 8-17 www.mymowerparts.com 8-1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame NOTE: Critical torque specifications are located in Section 1. Steering Post/Tie Rods FI465A 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 and LCD gauge. 3. Remove four reinstallable rivets securing the steering post cover and remove the cover. FI466A FI463A 4. Unlatch the storage compartment lid; then slide the storage compartment cover assembly forward and lift off. FI464A FI467A 2. Remove the reinstallable rivets securing the radiator access cover and remove the cover. www.mymowerparts.com 8-2 5. Remove the storage compartment. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI468 CD685 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. 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. CD762 AF778D 7. Remove two cap screws securing the upper steering post bearing to the frame. Account for two bearings and two housings. 8 KX039 CD760 10. Remove two cap screws securing the lower steering post bearing flange to the frame; then remove the steering post. 8. Using a suitable lift stand, raise the ATV enough to remove the front wheels. www.mymowerparts.com 8-3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AL600D CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 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 20 ft-lb. 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. ! 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. CD760 4. Inspect all welded areas for cracks or deterioration. 3. Install the tie rods and secure with the slotted nuts. Tighten to 30 ft-lb; then install new cotter pins. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 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. 6. Inspect the bearing halves, bearing caps, and bearing housings for cracks or wear. 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 20 ft-lb. AF778D 4. Install the front wheels and tighten to 40 ft-lb 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 securely. www.mymowerparts.com 8-4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the storage compartment box; then attach the storage compartment cover assembly by engaging the tabs into the slots and sliding rearward. Lock the storage compartment lid to hold the assembly in place. 7. Place the instrument pod into position; then secure with two reinstallable rivets and the ignition switch retaining ring. FI465A Handlebar Grip REMOVING FI464A 1. Loosen but do not remove the cap screws in the end of the handlebar; then tap lightly on the head to dislodge the handlebar plug. FI463A 8. Install the steering post access cover and secure with four reinstallable rivets; then install and secure the radiator access cover. KC310 8 KC309A FI466A 2. Grasp the end and remove the cap screw, plug, and end cap. INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. www.mymowerparts.com 1. Inspect the grip for wear, cuts, or cracks. 8-5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the grip for deterioration. 3. If a grip is damaged, cut the grip lengthwise using a sharp knife or box cutter; the peel off the grip. INSTALLING NOTE: Before installing a grip, use contact spray or alcohol to clean the handlebar of glue residue, oil, or any other contaminant. 1. Apply a liberal amount of Handlebar Grip Adhesive to the inside of a new grip. PR287A 2. Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up. 3. Wipe off any excess glue; then secure the grip with the handlebar end-cap. 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. 5. Remove the hub assembly. 1. Clean all knuckle components. 6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. 2. Inspect the bearing for pits, gouges, rusting, or premature wear. 7. Remove the two cap screws securing the ball joints in the knuckle. 3. Inspect the knuckle for cracks, breaks, or porosity. 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 4. Inspect threads for stripping or damage. ASSEMBLING AND INSTALLING 1. Install the bearing; then install the snap ring making sure it seats into the knuckle. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR287A PR290A 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb. 5. Install the hub assembly onto the splines of the shaft. 6. Secure the hub assembly with the nut. Tighten only until snug. AF628D 3. Install the tie rod end and secure with the nut. Tighten to 30 ft-lb; then install a new cotter pin and spread the pin. NOTE: During assembling, new cotter pins should be installed. PR257 7. Secure the brake caliper to the knuckle with the two cap screws. Tighten to 20 ft-lb. 8 PR264A AF618D 4. Apply a small amount of grease to the hub splines. 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 200 ft-lb. 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 40 ft-lb. 12. Remove the ATV from the support stand. www.mymowerparts.com 8-7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Measure the distance from the inside of each front rim to the lower frame tube. Measuring/ Adjusting Toe-In 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. 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. AF785D 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 equal reference points on each. 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. DE047A 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. AF617D CD014 www.mymowerparts.com 8-8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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). 733-559A Front Rack REMOVING 1. Remove the cap screws and lock nuts securing the rack to the frame and front fender panel. 2. 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 using a pressure washer. 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. 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 11. The difference in the measurements must show 1/8-1/4 in. toe-in (the front measurement 1/8-1/4 in. less than the rear measurement). 1. Place the rack into position on the frame and front fender panel. Install the cap screws and lock nuts and finger-tighten only. 12. If the difference in the measurements is not within specifications, adjust both tie rods equally until within specifications. 2. Install the two cap screws and lock nuts securing the rack to the fenders. Tighten all hardware securely. 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. Front Bumper Assembly REMOVING 1. Remove the two flange bolts and lock nuts securing the upper bumper supports to the bumper. www.mymowerparts.com 2. Remove the through-bolt and lock nut securing the bumper to the frame; then remove the bumper. 8-9 8 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. 2. Unlock the storage compartment lid; then slide the storage compartment cover assembly forward and lift off the storage compartment. 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. FI467 3. Remove the storage compartment box; then remove the seat. Front Body Panel/ Side Panels 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. FI468 4. Remove the ignition switch retaining ring and two reinstallable rivets securing the instrument pod; then remove the instrument pod. FI465A FI463A FI466A www.mymowerparts.com 8-10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI464A FI470A 5. Remove the cap screws and lock nuts securing the front rack to the frame; then remove the front rack. Account for the grommets and bushings. 7. Remove the left and right footwells; then remove the shift knob. Remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. FI469A 6. Remove the side panels by pulling on them to release the tabs from the body; then remove the screws securing the rear of the front panel to the frame. CD779 8 CD780A CF237A 8. Disconnect four headlight connectors and secure the wires out of the way; then disconnect the wires to the front accessory plug. www.mymowerparts.com 8-11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD681 CD765 9. 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. 2. Connect the headlight connectors to the appropriate headlights and the front accessory plug wires to the accessory plug. 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 rubber grommets and bushings are in place; then place the front rack into position and secure with the cap screws and lock nuts. Tighten securely. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 4. Install the footwells and foot rests. Tighten securely. 5. Install the cap screws securing the front body panel to the frame and rear panel. 1. Clean all fender components with warm soap and water. 2. Inspect fenders for cracks and/or loose rivets. 3. Inspect for any missing decals. INSTALLING 1. Rotate the handlebar to the full-left position; then place the front body panel over the handlebar and rotate and lower into position. FI470A 6. Install the shift lever spring, shift lever, and pivot axle; then tighten the axle nut securely. www.mymowerparts.com 8-12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD779 FI466A 7. Install the instrument pod and ignition switch; then secure with two reinstallable rivets and the ignition switch retaining ring. 8. Set the storage compartment box into position; then install the storage compartment cover making sure the mounting tabs engage the slots. Slide rearward to secure and lock by engaging the lid lock. FI465A 10. Install the side panels. Footrests FI468 REMOVING 1. Remove the machine screws and flange nuts securing the front and rear fenders to the footwells. 8 FI467 9. Install the steering post cover and secure with the reinstallable rivets; then install and secure the radiator access panel. CD691A 2. Remove the screws securing the foot pegs to the footrests; then remove the foot pegs and footwells. 3. Remove the cap screws and flange nuts securing the footrests to the frame; then remove the footrests. www.mymowerparts.com 8-13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING 2. Slide the muffler rearward to clear the mounting lugs and remove the muffler. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 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 the 8 mm hardware to 20 ft-lb and the 10 mm hardware to 40 ft-lb. 2. Place the footwells onto the footrests; then put the foot pegs in position and secure with two cap screws. 3. Install the machine screws and flange nuts securing the front and rear fenders to the footwells. 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. 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. Belly Panel Rear Body Panel/Rack 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. REMOVING 1. Remove the cap screws and lock nuts securing the rear rack; then remove the rear rack. Account for the bushings. 2. Remove one shoulder screw and lock nut and three plastic rivets (on each side) securing the rear body panel to the footwells. Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muffler/exhaust pipe juncture. CD691A 3. Remove two machine screws securing the battery cover and remove the cover. www.mymowerparts.com 8-14 CF138A FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD687A CD691 4. Disconnect the battery (negative cable first); then remove the battery. 4. Place the battery into the battery box; then connect the battery (positive cable first) and secure with the battery cover. 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. CD687A 1. Clean all rear body panel components with warm soap and water. 5. Secure the front and rear panels with two machine screws; then install the left and right side panels. 2. Inspect side panels and rear body panel for cracks and loose rivets. NOTE: If the front body panel has not been installed, see Front Body Panel/Side Panels in this section. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals. 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 the bushings and secure with the cap screws and lock nuts. Tighten securely. 3. Install one shoulder screw and three plastic rivets (on each side) to secure the front of the rear body panel to the footwells. 6. Place the seat into position making sure it locks securely. 8 Taillight Assembly REMOVING 1. Unplug the three-prong connector and free the taillight wiring harness from the frame. 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. www.mymowerparts.com 8-15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. CF227A 3. Route the wiring harness over the rear frame; then connect the three-prong connector. 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. Seat 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. CF229A REMOVING/INSTALLING (TRV) 1. To remove the rear seat, pull the two latch handles to the rear and rotate them to the vertical position. 4. Lock the seat into position by pulling the two latch handles to the rear and rotating them to the horizontal position. CF226A CF226 2. Lift the rear of the seat up; then pull slightly to the rear and lift the seat off the mountings. 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. www.mymowerparts.com 8-16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting 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. Cap screws - nuts loose 2. Wheel hub bearings broken - damaged 3. Lubrication inadequate 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 8 www.mymowerparts.com 8-17 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 Front Differential Lock Cable (500).......................... 9-4 Shift Lever ............................................................... 9-4 Speedometer/Tachometer/LCD............................... 9-5 www.mymowerparts.com 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. 4. Inspect the banjo-fitting for cracks and deterioration and the condition of the fittings (threaded and compression). DE059A ! CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV. 3. Remove the snap ring 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 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. Tighten to 20 ft-lb. 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 snap ring. 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 AF678D 9-3 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 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. AF679D 2. Using a pair of needle-nose pliers, place the spring into position on the actuator arm. 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. Shift Lever AF680D 3. Place the two halves of the throttle control onto the handlebar and secure with the two machine screws. ADJUSTING To adjust throttle cable free-play, see Section 4. Front Differential Lock Cable (500) 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 1/4 in. of free-play measured at the end of the differential lock lever. www.mymowerparts.com 9-4 REMOVING 1. Remove the E-clip securing the shift rod to the shift lever. 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. INSTALLING 1. 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. 2. Place the shift rod into position on the shift lever and secure with the existing E-clip. 3. Check shift lever adjustment (see Section 2); then tighten jam nut(s) securely. 4. Install the left-side splash panel. FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 4. Install the instrument pod and secure with the reinstallable rivets. 5. Secure the ignition switch with the retaining ring. 9 www.mymowerparts.com 9-5
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