Arctic_cat_2012_425_service_manual Arctic Cat 2012 425 Service Manual

User Manual: arctic_cat_2012_425_service_manual

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FOREWORD
TABLE OF CONENTS

FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-

tic Cat 425 ATV model. The complete manual is designed to aid service personnel in service-oriented applications.

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. A

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 photo-

graphs 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.

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

SHARE OUR PASSION.

Manual

Service M

ervice

425

TABLE OF CONENTS

General Information ............................................................. 2

General Specifications............................................................ 2

Torque Specifications ............................................................. 3

Torque Conversions (ft-lb/N-m)............................................... 4

Break-In Procedure ................................................................ 4

Gasoline - Oil - Lubricant........................................................ 4

Genuine Parts......................................................................... 5

Preparation For Storage ......................................................... 5

Preparation After Storage....................................................... 6

Periodic Maintenance .......................................................... 7

Periodic Maintenance Chart ................................................... 7

Lubrication Points ................................................................... 8

Air Filter .................................................................................. 8

Valve/Tappet Clearance.......................................................... 9

Testing Engine Compression................................................ 10

Spark Plug ............................................................................ 10

Liquid Cooling System.......................................................... 11

Muffler/Spark Arrester .......................................................... 11

Adjusting Throttle Cable ....................................................... 11

Adjusting Engine RPM (Idle) ................................................ 12

Engine/Transmission Oil - Filter ........................................... 12

Front Differential/Rear Drive Lubricant ................................. 13

Tires...................................................................................... 13

Driveshaft/Coupling .............................................................. 14

Nuts/Bolts/Cap Screws......................................................... 14

Ignition Timing ...................................................................... 14

Lights .................................................................................... 14

Shift Lever............................................................................. 16

Frame/Welds/Racks.............................................................. 16

Hydraulic Brake Systems...................................................... 16

Burnishing Brake Pads ......................................................... 18

Checking/Replacing V-Belt .................................................. 18

Engine/Transmission.......................................................... 21

Troubleshooting .................................................................... 22

Removing Engine/Transmission ........................................... 24

Top-Side Components .......................................................... 25

Removing Top-Side Components ......................................... 26

Servicing Top-Side Components .......................................... 29

Installing Top-Side Components........................................... 36

Left-Side Components.......................................................... 39

Removing Left-Side Components......................................... 40

Servicing Left-Side Components.......................................... 42

Installing Left-Side Components........................................... 44

Right-Side Components ....................................................... 46

Removing Right-Side Components ...................................... 46

Servicing Right-Side Components........................................ 49

Installing Right-Side Components ........................................ 50

Center Crankcase Components ........................................... 52

Separating Crankcase Halves .............................................. 52

Disassembling Crankcase Half............................................. 53

Servicing Center Crankcase Components ........................... 54

Assembling Crankcase Half.................................................. 59

Joining Crankcase Halves .................................................... 61

Installing Engine/Transmission ............................................. 62

Fuel/Lubrication/Cooling .................................................... 64

Electronic Fuel Injection ....................................................... 64

Throttle Body ........................................................................ 64

Throttle Cable Free-Play....................................................... 64

Gas Tank .............................................................................. 65

Oil Filter/Oil Pump ................................................................ 66

Testing Oil Pump Pressure ................................................... 66

Liquid Cooling System ..........................................................67

Electric Fuel Pump/Fuel Level Sensor ..................................69

Troubleshooting .....................................................................71

Electrical System................................................................72

Electrical Connections...........................................................72

Battery...................................................................................72

RPM Limiter ..........................................................................73

Testing Electrical Components..............................................73

Accessory Receptacle/Connector.........................................73

Brakelight Switch (Pressure) .................................................73

Fan Motor ..............................................................................74

Fuse Block/Power Distribution Module..................................75

Ignition Coil ...........................................................................75

Speed Sensor .......................................................................76

Ignition Switch .......................................................................77

Handlebar Control Switches..................................................77

Front Drive Selector Switch...................................................78

Front Drive Selector Actuator ................................................78

Gear Position Switch .............................................................78

Stator Coil .............................................................................79

Starter Relay .........................................................................79

Starter Motor .........................................................................80

Electronic Control Unit (ECU) ...............................................80

Regulator/Rectifier ................................................................80

Lights.....................................................................................81

Ignition Timing.......................................................................82

Tilt Sensor .............................................................................82

Throttle Position Sensor (TPS)..............................................83

Diagnostic Trouble Codes (DTC) ..........................................85

Troubleshooting .....................................................................87

Drive System ......................................................................88

Front Drive Actuator ..............................................................88

Front Differential....................................................................89

Drive Axles ............................................................................99

Rear Gear Case ..................................................................101

Hub......................................................................................101

Hand Brake Lever/Master Cylinder Assembly.....................102

Hydraulic Brake Caliper.......................................................102

Troubleshooting Drive System.............................................105

Troubleshooting Brake System............................................106

Suspension.......................................................................107

Shock Absorbers.................................................................107

Front A-Arms.......................................................................107

Rear A-Arms .......................................................................108

Wheels and Tires ................................................................109

Troubleshooting ...................................................................110

Steering/Frame/Controls ..................................................111

Steering Post/Tie Rods .......................................................111

LCD Gauge .........................................................................112

Handlebar Grip....................................................................113

Throttle Control ...................................................................113

Steering Knuckles ...............................................................114

Measuring/Adjusting Toe-Out..............................................116

Front Rack...........................................................................116

Front Bumper Assembly......................................................117

Front Body Panel/Fender ....................................................117

Exhaust System ..................................................................118

Rear Body Panel/Rack ........................................................119

Seat.....................................................................................120

Troubleshooting ...................................................................121

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the

Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page,

click the Manual Table of Contents button at the bottom of each page.

Click on the blue text to go.

General Information

NOTE: Some photographs and illustrations used in

this manual are used for clarity purposes only and

are not designed to depict actual conditions.

General Specifications

Specifications subject to change without notice.

* One inch below plug threads.

** At the plug threads.

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 27.6 kPa (4 psi)

MISCELLANY

Spark Plug Type CR7E

Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)

Gas Tank Capacity (rated) 15.1 L (4.0 U.S. gal.)

Rear Drive Capacity 250 ml (8.5 fl oz)*

Front Differential Capacity 275 ml (9.3 fl oz)**

Coolant Capacity 2.9 L (3.0 U.S. qt)

Engine Oil Capacity 3.3 L (3.5 U.S. qt) - Overhaul

2.8 L (3.0 U.S. qt) - Change

Gasoline (recommended) 87 Octane Regular Unleaded

Engine Oil (recommended) Arctic Cat ACX All Weather

(Synthetic)

Differential/Rear Drive Lubricant SAE Approved 80W-90

Hypoid

Drive Belt Width (minimum) 28.5 mm (1.12 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/5W/21W

Headlight 12V/35W (4)

IGNITION

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type NGK CR7E

Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)

Spark Plug Cap 5000 ohms

Ignition Coil Resistance (primary)

(secondary)

Less than 5.0 ohms (terminal

(+) to terminal (-))

12k-19k ohms (high tension -

plug cap - to terminal (+))

Ignition Coil Primary Voltage Battery Voltage

(orange (+) to blue/white(-))

MAGNETO

Stator Coil Resistance (CKP Sensor)

(AC generator)

150-250 ohms (blue to

green)

Less than 1 ohm (yellow to

yellow)

AC Generator Output (no load) 60 AC volts @ 5000 RPM

(yellow to yellow)

Crankshaft Position Sensor AC Voltage 2.5 volts or more (blue to

green)

CRANKSHAFT

Connecting Rod (small end) (max) 20.021 mm

Connecting Rod (big end side-to-side)

(max)

0.7 mm

Connecting Rod (big end width) 21.95-22.00 mm

Connecting Rod (small end deflection)

(max)

3.0 mm

Crankshaft (web-to-web) 60.9 mm

Crankshaft Runout (max) 0.03 mm

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance 0.025-0.055 mm

Piston Diameter 8 mm from Skirt End 88.96-88.98 mm

Piston Ring Free End Gap (max) (1st)

(2nd)

11.6 mm

10.1 mm

Bore x Stroke 89.0 x 71.2 mm

Cylinder Trueness (max) 0.01 mm

Piston Ring End Gap - Installed (min) 0.15 mm

Piston Ring to Groove Clearance (max)

(1st/2nd)

0.06 mm

Piston Ring Groove Width (1st)

(2nd)

(oil)

1.01-1.03 mm

1.21-1.23 mm

2.01-2.03 mm

Piston Ring Thickness (1st)

(2nd)

0.97-.99 mm

1.17-1.19 mm

Piston Pin Bore (max) 20.008 mm

Piston Pin (min) 19.994 mm

VALVES AND GUIDES )

Valve Face Diameter (intake)

(exhaust)

35.0 mm

30.5 mm

Valve/Tappet Clearance (intake)

(cold engine) (exhaust)

0.10 mm

0.17 mm

Valve Guide/Stem (intake)

Clearance (max) (exhaust)

0.10 mm

0.30 mm

Valve Guide/Valve Stem Deflection

(Wobble Method) (Max)

0.035 mm

Valve Face Radial Runout (max) 0.15 mm

Valve Guide Inside Diameter 5.000-5.012 mm

Valve Stem Outside Diameter (intake)

(exhaust)

4.975-4.990 mm

4.955-4.970 mm

Valve Stem Runout (max) 0.10 mm

Valve Face/Seat Width (min)

(intake/exhaust)

0.99 mm

Valve Seat Angle (intake/exhaust) 45°

Valve Spring Free Length (min) 44.73 mm

Valve Spring Tension @ 35.2 mm 17.23 kg (37.98 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

34.71 mm

34.48 mm

Camshaft Journal Holder (right & center)

Inside Diameter (left)

22.01-22.04 mm

17.51-17.54 mm

Camshaft Journal Outside (right & center)

Diameter (left)

17.466-17.480 mm

21.966- 21.980 mm

Camshaft Runout (max) 0.03 mm

Rocker Arm Inside Diameter 10.00-10.15 mm

Rocker Arm Shaft Outside Diamter 9.972-9.987 mm

Cylinder Head/Cover Distortion (max) 0.05 mm

Camshaft Journal/Cylinder Head

Clearance (max)

0.074 mm

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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Torque Specifications

* w/Blue Loctite #243

** w/Red Loctite #271

*** w/Green Loctite #609

EXHAUST COMPONENTS

Part Part Bolted To Torque

ft-lb N-m

Exhaust Pipe Engine 20 27

Spark Arrester Muffler 48

in.-lb

5.5

ELECTRICAL COMPONENTS

Coil Frame 12 16

Starter Motor Positive Cable Starter Motor 811

CHASSIS COMPONENTS

Footrest Frame (8 mm) 20 27

Bumper Frame (8 mm) 20 27

ENGINE/TRANSMISSION

Clutch Shoe** Crankshaft 147 199

Clutch Cover/Housing Assembly Crankcase 811

Left-Side Cover Crankcase 811

Crankcase Half (6 mm) Crankcase Half 10 13.5

Crankcase Half (8 mm) Crankcase Half 21 28

Cylinder Nut Crankcase Half 811

Cylinder Head (Cap Screw) Crankcase 28 38

Cylinder Head Nut Cylinder 20 27

Cylinder Head Cover Cylinder Head 811

Oil Pump Drive Gear** Crankshaft 63 86

Driven Pulley Nut** Driveshaft 147 199

Ground Cable Engine 811

Magneto Rotor Nut Crankshaft 107 146

Cam Sprocket** Camshaft 11 15

Valve Adjuster Jam Nut Valve Adjuster 79.5

Starter Motor Crankcase 811

Oil Fitting Engine 811

Starter One-Way Clutch Flywheel 26 35

Oil Pump* Crankcase 811

Movable Drive Face Nut** Clutch Shaft 147 199

Output Shaft Flange Nut Output Shaft 59 80

Cam Chain Tensioner Guide Cylinder 11 15

Valve Inspection Cover Cylinder Head Cover 811

Cam Chain Tensioner Cylinder 10 13.5

Magneto Cover Crankcase 811

Rear Driveline Output Drive Flange 20 27

Water Pump Cover/Housing Magneto Cover 811

Water Pump Drive Gear Crankshaft 28 38

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

Master Cylinder (Rear) Frame 811

Master Cylinder Clamp (Front) Master Cylinder 5.5 8

Hydraulic Caliper Knuckle 20 27

Auxiliary Brake Pedal Pivot 20 27

STEERING COMPONENTS

Steering Post Bearing Housing Frame 20 27

Handlebar Cap Steering Post 20 27

Lower Steering Post Bearing

Cap Screw

Steering Post 40 54

Tie Rod End** Steering Post Arm 30 41

DRIVE TRAIN COMPONENTS

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 Output Flange Joint 20 27

Input Shaft Housing Differential Housing 18 25

Pinion Housing Gear Case Housing 18 25

Differential Housing Cover*** Differential Housing 18 25

Drive Bevel Gear Nut** Shaft 59 80

Driven Bevel Gear Nut** Driven Shaft 59 80

Thrust Button Gear Case Cover 811

Hub Nut Shaft/Axle (max) 200 272

Oil Drain Plug Front Differential/Rear

Drive

in.-lb

Oil Fill Plug Front Differential/Rear

Drive

16 22

Oil Drain Plug Engine 20 27

Rear Drive Input Shaft Housing Differential Housing 23 31

Lock Collar Differential Housing 125 169

Wheel (Steel) Hub 40 54

Wheel (Aluminum) Hub 80 108

Rear Drive Gear Case Frame 38 52

Engine Output Flange Rear Gear Case Input

Flange 20 27

SUSPENSION COMPONENTS (Front)

A-Arm Frame 35 47

Knuckle Ball Joint 35 47

Shock Absorber Frame 35 47

Shock Absorber Upper A-Arm 35 47

Knuckle A-Arm 35 47

SUSPENSION COMPONENTS (Rear)

Shock Absorber (Upper) Frame 35 47

Shock Absorber (Lower) Lower A-Arm 35 47

A-Arm Frame 35 47

Knuckle A-Arm 35 47

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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Torque Conversions

(ft-lb/N-m)

Break-In Procedure

A new ATV and an overhauled ATV engine require a

“break-in” period. The first 10 hours (or 200 miles) are

most critical to the life of this ATV. Proper operation dur-

ing 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 dur-

ing 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 etha-

nol 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.

RECOMMENDED ENGINE/

TRANSMISSION OIL

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 0W-40 oil is acceptable.

OILCHARTJ

ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m

11.4 26 35.4 51 69.4 76 103.4

22.7 27 36.7 52 70.7 77 104.7

34.1 28 38.1 53 72.1 78 106.1

45.4 29 39.4 54 73.4 79 107.4

56.8 30 40.8 55 74.8 80 108.8

68.2 31 42.2 56 76.2 81 110.2

79.5 32 43.5 57 77.5 82 111.5

810.9 33 44.9 58 78.9 83 112.9

912.2 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

CAUTION

Do not use white gas. Only Arctic Cat approved gaso-

line additives should be used.

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 recom-

mended are racing, vegetable, non-detergent, and cas-

tor-based oils.

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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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.

FILLING 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.

ATV0049B

Tighten the gas tank cap securely after filling the tank.

Genuine Parts

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 Illustrated Parts

Manual for the correct part number, quantity, and

description.

Preparation For Storage

Arctic Cat recommends the following procedure to pre-

pare 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.

4.Plug the exhaust outlet on the muffler with a clean

cloth.

5. Apply light oil to the upper steering post bushing and

plungers of the shock absorbers.

6. 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.

7. Fill the cooling system to the bottom of the stand

pipe in the radiator neck with properly mixed cool-

ant.

8. Disconnect the battery cables; then remove the bat-

tery, clean the battery posts and cables, and store in a

clean, dry area.

9. Store the ATV indoors in a level position.

CAUTION

Any lubricant used in place of the recommended lubri-

cant could cause serious front differential/rear drive

damage.

! 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.

! 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.

CAUTION

Prior to storing the ATV, it must be properly serviced to

prevent rusting and component deterioration.

CAUTION

If the interior of the air filter housing is dirty, clean the

area before starting the engine.

CAUTION

Avoid storing outside in direct sunlight and avoid using

a plastic cover as moisture will collect on the ATV caus-

ing rusting.

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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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 pre-

pare the ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from the muffler.

3. Check all control cables for signs of wear or fraying.

Replace if necessary.

4. Change the engine/transmission oil and filter.

NOTE: At this point, check the coolant level and add

properly mixed coolant as necessary.

5. Charge the battery; then install. Connect the battery

cables.

6. Check the entire brake systems (fluid level, pads,

etc.), all controls, lights, and headlight aim; adjust or

replace as necessary.

7. Tighten all nuts, bolts, cap screws, and screws mak-

ing sure all calibrated nuts, cap screws, and bolts are

tightened to specifications.

8. Check tire pressure. Inflate to recommended pressure

as necessary.

9. Make sure the steering moves freely and does not

bind.

10. Check the spark plug. Clean or replace as necessary.

CAUTION

The ignition switch must be in the OFF position prior to

installing the battery or damage may occur to the igni-

tion system.

CAUTION

Connect the positive battery cable first; then the nega-

tive.

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Periodic Maintenance

This section has been organized into sub-sections which show

common maintenance procedures for the Arctic Cat ATV.

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Periodic Maintenance

Chart

A = AdjustI = Inspect C = CleanL = Lubricate D = DrainR = Replace T = Tighten

* 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.

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

Item

Initial Service After

Break-In (First Mo or

100 Mi)

Every

Day

Every Month or

100 Miles

Every 3

Months or

300 Miles

Every 6

Months or

500 Miles

Every Year

or 1500

Miles

As Needed

Battery II C

Fuses IR

Air Filter/Drain Tube IIC* R

Valve/Tappet Clearance IIA

Engine Compression I

Spark Plug I I R (4000 Mi

or 18 Mo)

Muffler/Spark Arrester CR

Gas Hoses II R (2 Yrs)

Throttle Cable II C-L A-R

Engine-Transmission Oil Level IA

Engine-Transmission Oil/Filter R R*/R**/R***

Front Differential/Rear Drive Lubricant II R (4 Yrs)

Tires/Air Pressure II R

Steering Components II I R

V-Belt IlR

Suspension (Ball joint boots, drive axle boots front

and rear, tie rods, differential and rear drive bellows)

II R

Nuts/Cap Screws/Screws II A

Ignition Timing I

Lights II R

Switches II R

Shift Lever IA-L

Handlebar Grips IR

Handlebar II R

Gauges/Indicators II R

Frame/Welds/Racks Il

Electrical Connections IlC

Complete Brake System

(Hydraulic & Auxiliary)

II C L-R

Brake Pads II*R

Brake Fluid IIR (2 Yrs)

Brake Hoses IIR (4 Yrs)

Coolant/Coolant System II R (2 Yrs)

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the

components using the following list as reference.

A. Throttle Lever Pivot/Cable Ends

B. Brake Lever Pivot/Cable Ends

C. Auxiliary Brake Cable Ends

Air Filter

CLEANING AND INSPECTING

FILTER

1. Rotate the three locking tabs free of the lugs on the

air filter cover; then rotate the cover forward and

away from the filter housing.

KC0056A

KC147

2. Remove the foam filter element from the air filter

housing and separate the foam element from the

spring.

KC148

KC143

3. 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.

4. Dry the element.

5. Put the element in a plastic bag; then pour in air filter

oil and work the oil into the element. Insert the form-

ing spring into the element with the closely wrapped

end of the spring toward the open end of the element.

6. Clean any dirt or debris from inside the air cleaner.

7. Place the filter assembly in the air filter housing

making sure it is properly positioned and properly

seated with the filter element straight in the housing.

KC147

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.

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8. Install the air filter housing cover and secure with the

locking tabs.

KC123

CHECKING AND CLEANING DRAIN

1. Inspect the drain on the filter housing cover and

clean out any dirt or debris.

KC0056C

2. Replace any drain that is cracked or shows any signs

of hardening or deterioration.

3. Wipe any accumulation of oil or gas from the filter

housing and drain.

Valve/Tappet Clearance

To check and adjust valve/tappet clearance, use the fol-

lowing procedure.



NOTE: The seat, left-side and right-side engine cov-

ers, and gas tank must be removed for this procedure.

1. Remove the timing inspection plug and spark plug;

then remove the valve inspection covers (for more

detailed information, see Engine/Transmission - Ser-

vicing Top-Side Components).

CF005

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.

Feeler Gauge Procedure

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 clear-

ance is within specifications. Tighten each jam nut

securely after completing the adjustment.

CC007DC

Valve Adjuster Procedure

A. Place the Valve Clearance 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.

B. 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.

C. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

CAUTION

Failure to properly seat and align the filter element may

cause severe engine damage.

CAUTION

The feeler gauge must be positioned at the same angle

as the valve and valve adjuster for an accurate measure-

ment of clearance. Failure to measure the valve clear-

ance accurately could cause valve component damage.

VALVE/TAPPET CLEARANCE

Intake 0.076-0.127 mm (0.003-0.005 in.)

Exhaust 0.152-0.203 mm (0.006-0.008 in.)

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D. 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 counter-

clockwise will open the valve/tappet clearance by

0.05 mm (0.002 in.) per mark.

E. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

3. Place the two valve inspection covers with O-rings

into position; then tighten the covers securely.

4. Install the spark plug; then install the timing inspec-

tion plug.

Testing Engine

Compression

To test engine compression, use the following procedure.

1. Remove the high tension lead from the spark plug.

2. Using compressed air, blow any debris from around

the spark plug.

3. Remove the spark plug; then attach the high tension

lead to the plug and ground the plug on the cylinder

head well away from the spark plug hole.

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 posi-

tion, crank the engine over with the electric starter

until the gauge shows a peak reading of 95-115 psi

(five to 10 compression strokes).

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 Engine/Transmission.

7. Pour approximately 30 ml (1 fl oz) of oil into the spark

plug hole, reattach the gauge, and retest compression.

8. If compression is now evident, service the piston

rings (see Engine/Transmission).

Spark Plug

A light brown insulator indicates that a plug is correct. A

white or dark insulator indicates that the engine may need

to be serviced. To maintain a hot, strong spark, keep the

plug free of carbon.

ATV-0051

Adjust the gap to specification (see General Information

section). Use a feeler gauge to check the gap.

ATV0052

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.

! WARNING

Always wear safety glasses when using compressed

air.

CAUTION

Before removing a spark plug, be sure to clean the area

around the spark plug. Dirt could enter engine when

removing or installing the spark plug.

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Liquid Cooling System



NOTE: Debris in front of the engine or packed between

the cooling fins of the radiator can reduce cooling capa-

bility. Using a garden hose, wash the radiator to remove

any debris preventing air flow.

The cooling system capacity can be found in the specifi-

cations chart. The cooling system should be inspected

daily for leakage and damage. If leakage or damage is

detected, take the ATV to an authorized Arctic Cat ATV

dealer for service. Also, the coolant level should be

checked periodically.

NOTE: High engine RPM, low vehicle speed, or

heavy load can raise engine temperature. Decreasing

engine RPM, reducing load, and selecting an appro-

priate transmission gear can lower the temperature.

When filling the cooling system, use a coolant/water

mixture which will satisfy the coldest anticipated weather

conditions of the area in accordance with the coolant

manufacturer’s recommendations. While the cooling sys-

tem 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 bot-

tom of the stand pipe in the radiator neck.

Checking/Filling

1. Locate the coolant reservoir on the right side behind

the radiator.

KC338B

2. Remove the cap and fill with the appropriate coolant

until coolant level is between the LOW and FULL

lines. Do not overfill.

3. Install the cap on the reservoir.

Muffler/Spark Arrester

At the intervals shown in the Periodic Maintenance

Chart, clean the spark arrester using the following proce-

dure.

1. Remove the cap screws securing the spark arrester

assembly to the muffler; then loosen and remove the

arrester.

KC334A

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 cap screws. Tighten to 48 in.-lb.

KC145

Adjusting Throttle Cable

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.

CAUTION

Arctic Cat does not recommend using a pressure washer

to clean the radiator core. The pressure may bend or flat-

ten the fins causing restricted air flow, and electrical com-

ponents on the radiator could be damaged. Use only a

garden hose with spray nozzle at normal tap pressure.

CAUTION

Continued operation of the ATV with high engine temper-

ature may result in engine damage or premature wear.

! WARNING

Wait until the muffler cools to avoid burns.

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AL611D

2. Turn the adjuster until the throttle cable has proper

free-play of 3-6 mm (1/8-1/4 in.) at the lever.

ATV-0047

3. Tighten the jam nut against the throttle cable adjuster

securely; then slide the rubber boot over the adjuster.

Adjusting Engine RPM

(Idle)



NOTE: Engine idle RPM is not adjustable on this

model.

Engine/Transmission

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 seat and left-side engine cover.

3. Remove the oil level stick/filler plug.

KC0051A

4. Remove the drain plug from the bottom of the engine

and drain the oil into a drain pan.

733-441A

5. 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.

6. 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.

7. Apply oil to a new filter seal ring and check to make

sure it is positioned correctly; then install the new oil

filter. Tighten securely.

8. Install the engine drain plug and tighten to 20 ft-lb.

Pour the specified amount of the recommended oil in

the filler hole. Install the oil level stick/filler plug.

9. Start the engine (while the ATV is outside on level

ground) and allow it to idle for a few minutes.

10. Turn the engine off and wait approximately one minute.

11. Remove the oil level stick and wipe it with a clean

cloth; then install the oil level stick into engine case.

NOTE: The oil level stick should be threaded into

the case for checking purposes.

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 recom-

mended are racing, vegetable, non-detergent, and cas-

tor-based oils.

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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.

ATV-0100AA

13. Inspect the area around the drain plug and oil filter

for leaks.

14. Install the left-side engine cover and the seat.

Front Differential/Rear

Drive Lubricant

When changing the lubricant, use approved SAE 80W-90

hypoid gear lube.

To check lubricant, remove the rear drive filler plug; the

lubricant level should be 1 in. below the threads of the

plug. If low, add SAE approved 80W-90 hypoid gear

lubricant as necessary.

To change the lubricant, use the following procedure.

1. Place the ATV on level ground; then remove each fill

plug.

KC0077A

2. Drain the lubricant into a drain pan by removing the

drain plug from each.

ATV0082A

737-651B

3. After all the oil has been drained, install the drain

plugs and tighten to 45 in.-lb.

4. Pour the appropriate amount of approved SAE

80W-90 hypoid gear lubricant into the filler hole.

5. Install the fill plugs and tighten to 16 ft-lb.

NOTE: If the differential/rear drive oil is contami-

nated with water, inspect the drain plug, filler plug,

and/or bladder.

Tires

TIRE SIZES

The ATV is equipped with low-pressure tubeless tires of

the size and type listed (see General Information section).

Do not under any circumstances substitute tires of a dif-

ferent type or size.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 27.6 kPa

(4.0 psi).

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.

CAUTION

Water entering the outer end of the axle will not be able

to enter the rear drive unless the seals are damaged.

! WARNING

Always use the size and type of tires specified. Always

maintain proper tire inflation pressure.

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Driveshaft/Coupling

The following drive system components should be

inspected periodically to ensure proper operation.

A. Spline lateral movement (slop).

B. Coupling cracked, damaged, or worn.

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.

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.

1. Attach the Timing Light to the spark plug high ten-

sion 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 dam-

aged, the key may be sheared, the trigger coil bracket may

be bent or damaged, or the CDI unit/ECU may be faulty.

Lights

Rotate the ignition switch to the lights position; the head-

lights and taillights should illuminate. Test the brake-

lights by compressing the brake lever. The brakelights

should illuminate.

HEADLIGHTS



NOTE: The bulb portion of a headlight is fragile. HAN-

DLE 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.

To replace the headlight bulb, use the following proce-

dure.

1. Remove the protective rubber boot from the rear of

the headlight housing; then remove the wiring har-

ness connector from the back of the headlight bulb.

KC146A

KC162

2. Press in and release the spring retainer and pull rear-

ward clear of the bulb assembly.

KC163A

3. Remove the headlight bulb assembly from the head-

light housing.

4. Install the new headlight bulb into the headlight

housing being careful not to get fingerprints or other

contaminates on the glass; then secure with the

spring.

! WARNING

Do not attempt to remove a bulb when it is hot. Severe

burns may result.

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KC163B

5. Connect the wiring harness connector to the bulb;

then install the protective rubber boot making sure it

seals completely on the headlight harness.

KC146

TAILLIGHTS-BRAKELIGHTS

To replace a taillight-brakelight bulb, use the following

procedure.

1. Turn the bulb socket assembly counterclockwise and

remove from the housing.

KC157

2. Press in and turn the bulb counterclockwise to remove.

Press in and turn clockwise to install the bulb.

3. Insert the bulb socket assembly into the housing and

turn it clockwise to secure.

RUNNING LIGHTS/BACK-UP LIGHTS

The running lights are located outboard of the headlights,

and the back-up lights are outboard of the taillights/brake-

lights. To replace the bulbs, use the following procedure.

1. Rotate the bulb socket counterclockwise to release

from light housing; then press in on the bulb and turn

counterclockwise to release from the socket.

KC158A

2. Install a new bulb and press in rotating clockwise to

secure; then place the socket into the light housing

and turn clockwise to secure.

KC158B

CHECKING/ADJUSTING HEADLIGHT

AIM

The headlights can be adjusted vertically and horizon-

tally. 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 sur-

face (wall or similar aiming surface).

ATV-0070C

NOTE: There should be an average operating load

on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the mid-point

of each headlight.

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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 verti-

cal mark 5 cm (2 in.) below the horizontal mark on

the aiming surface.

7. Adjust each headlight by turning the adjuster screw

clockwise to raise the beam or counterclockwise to

lower the beam.

KC406A

Shift Lever

CHECKING ADJUSTMENT

KC165

With the engine stopped and the brake lever lock

engaged, turn the ignition switch to the ON position; then

shift the transmission into each of the gear positions and

note that the gear position indicated on the LCD corre-

sponds to the gear position selected by the lever.

If the indicator does not correspond to the selected gear,

it will be necessary to test drive the ATV to determine if

the gear position switch is faulty or the shift lever needs

adjustment.

If the ATV functions in the gear selected by the shift

lever, troubleshoot the gear position switch (see Electri-

cal System).

If the ATV functions but the shift lever does not corre-

spond with the gear indicated on the LCD, adjust the shift

linkage. To adjust, proceed to ADJUSTING.

ADJUSTING

1. Remove the seat; then remove the left-side engine

cover.

2. With the ignition switch in the ON position, loosen

jam nut (A) (left-hand threads); then loosen jam nut

adjust the coupler (B) until the transmission is in

reverse and the “R” icon appears on the LCD.

KC194A

3. Tighten the jam nuts securely; then shift the trans-

mission to each position and verify correct adjust-

ment.

4. Install the left-side engine cover and seat making

sure the seat locks securely in place.

Frame/Welds/Racks

The frame, welds, and racks should be checked periodi-

cally for damage, bends, cracks, deterioration, broken

components, and missing components. If replacement or

repair constitutes removal, see Steering/Frame.

Hydraulic Brake Systems

CHECKING/BLEEDING

The hydraulic brake systems have been filled and bled at

the factory. To check and/or bleed a hydraulic brake sys-

tem, 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.

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738-420A

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.

AF637D

PR377C

NOTE: During the bleeding procedure, watch the

appropriate reservoir 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.

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.

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 thick-

ness of each of the brake pads as follows.

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

3. If thickness of either brake pad is less than 1.0 mm

(0.039 in.), the brake pads must be replaced.

CAUTION

Brake fluid that has been drained or bled from the brake

system must NEVER be re-used or severe brake system

corrosion and damage may occur. Always discard used

brake fluid in an appropriate manner.

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.

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PR376B

NOTE: The brake pads should be replaced as a set.

4. To replace the brake pads, use the following procedure.

A. Remove the cap screws securing the caliper

holder to the knuckle; then remove the pads.

PR237

B. Install the new brake pads.

C. Secure the caliper to the knuckle and/or axle

housing with the cap screws. Tighten to 20 ft-lb.

PR377B

5. Install the wheel. Tighten to 40 ft-lb.

6. Burnish the brake pads (see Burnishing Brake Pads

in this section).

Burnishing Brake Pads

Brake pads (both main 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.

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 twenty

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.

Checking/Replacing

V-Belt

REMOVING

1. Remove the seat and right-side engine cover; then

remove the cap screw securing the auxiliary brake

pedal to the frame. Account for a flat washer.

KC149A

2. Slide the auxiliary brake pedal part way off the pivot

stud but do not remove; then remove the cap screws

from the V-belt housing and remove the cover.

Account for two alignment pins and a gasket.

! WARNING

Failure to properly burnish the brake pads could lead to

premature brake pad wear or brake loss. Brake loss can

result in severe injury.

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KC142A

3. Remove the nut securing the movable drive face to the clutch

shaft; then remove the movable drive face assembly being

careful not to let the roller fall out. Account for a bushing.

KC127

KC128

4. Thread a cap screw from the V-belt cover into the

driven pulley fixed face and push the movable face

open allowing the V-belt to drop down between the

pulley faces approximately 3/4 in.

KC137

5. Pinching the V-belt together in front of the driven

pulley, pull it forward and outward off the clutch

shaft; then remove it from the driven pulley.

KC136

6. Inspect the faces of the drive and driven pulleys for

scoring, pitting, cracks, or grooving; then clean any

dirt and debris from the V-belt housing and cover.

INSTALLING

1. Place the V-belt onto the driven pulley making sure

the arrows point in the direction of rotation; then

pinch the belt together in front of the driven pulley

and place it over the clutch shaft.

KC135

KC131

2. Install the bushing over the clutch shaft; then install

the movable drive face assembly on the clutch shaft.

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KC128

KC138

3. With two drops of red Loctite #271 on the threads

and with the splines of the clutch shaft protruding

through the movable drive face, install the nut and

tighten to 147 ft-lb.

KC152A

KC141

4. Remove the cap screw from the fixed driven face;

then rotate the pulleys counterclockwise until the

driven pulley faces are together.

5. With the two alignment pins installed in the V-belt

housing and a new V-belt cover gasket in place,

install the V-belt cover. Using the pattern shown,

secure with the cap screws tightened to 8 ft-lb.

KC142A

KC153A

6. Slide the auxiliary brake pedal fully onto the pivot

stud engaging the master cylinder; then secure with

the flat washer and cap screw and tighten to 20 ft-lb.

KC149A

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Engine/Transmission

This section has been organized into sub-sections which

show a progression for the complete servicing of the Arc-

tic Cat ATV engine/transmission.

To service the center crankcase halves, the engine/trans-

mission must be removed from the frame. To service

top-side, left-side, and right-side components, the

engine/transmission does not have to be removed from

the frame.

NOTE: Arctic Cat recommends the use of new gas-

kets, lock nuts, and seals and lubricating all internal

components when servicing the engine/transmis-

sion.

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Description p/n

Crankcase Separator/Crankshaft Remover 0444-152

Magneto Rotor Remover Set 0444-254

Oil Filter Wrench 0644-389

Piston Pin Puller 0644-328

Spanner Wrench 0444-251

Surface Plate 0644-016

V Blocks 0644-535

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Troubleshooting

Problem: Engine will not start or is hard to start (Compression too low)

Condition Remedy

1. Valve clearance out of adjustment

2. Valve guides worn

3. Valve timing incorrect

4. Piston rings worn excessively

5. Cylinder bore worn

6. Spark plug seating poorly

7. Starter motor cranks too slowly - does not turn

1. Adjust clearance

2. Replace cylinder head

3. Correct valve timing - check chain, sprockets, and cam chain

tensioner

4. Replace rings

5. Replace cylinder

6. Tighten plug

7. Check - replace starter motor

Problem: Engine will not start or is hard to start (No spark)

Condition Remedy

1. Spark plug fouled

2. Spark plug wet

3. Magneto defective

4. ECU defective

5. Ignition coil defective

6. High-tension lead open - shorted

1. Clean - replace plug

2. Clean - dry plug

3. Replace stator coil

4. Replace ECU

5. Replace ignition coil

6. Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the throttle body

Condition Remedy

1. Gas tank vent hose obstructed

2. Fuel hose obstructed

3. Fuel screens obstructed

4. Fuel pump defective

1. Clean vent hose

2. Clean - replace hose

3. Clean - replace inlet screen - valve screen

4. Replace fuel pump

Problem: Engine stalls easily

Condition Remedy

1. Spark plug fouled

2. Magneto defective

3. ECU defective

4. Valve clearance out of adjustment

1. Clean plug

2. Replace stator coil

3. Replace ECU

4. Adjust clearance

Problem: Engine noisy (Excessive valve chatter)

Condition Remedy

1. Valve clearance excessive

2. Valve spring(s) weak - broken

3. Rocker arm - rocker arm shaft worn

4. Camshaft worn

5. Valve tappets worn

1. Adjust clearance

2. Replace spring(s)

3. Replace arm - shaft

4. Replace camshaft

5. Replace tappets

Problem: Engine noisy (Noise seems to come from piston)

Condition Remedy

1. Piston - cylinder worn

2. Combustion chamber carbon buildup

3. Piston pin bore worn

4. Piston pin worn

5. Piston rings - ring groove(s) worn

1. Replace - service piston - cylinder

2. Clean chamber

3. Replace piston

4. Replace piston pin

5. 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

1. Replace chain

2. Replace sprockets

3. Repair - replace adjuster

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 crankshaft

3. Replace crankshaft

Problem: Engine noisy (Noise seems to come from transmission)

Condition Remedy

1. Gears worn - chipped

2. Splines worn

3. Primary gears worn - chipped

4. Bearings worn

5. Bushing worn

1. Replace gears

2. Replace shaft(s)

3. Replace gears

4. Replace bearings

5. Replace bushing

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Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)

Condition Remedy

1. Drive - driven bevel gears damaged - worn

2. Backlash excessive

3. Tooth contact improper

4. Bearing damaged

5. Gears worn - chipped

6. Splines worn

1. Replace gears

2. Adjust backlash

3. Adjust contact

4. Replace bearing

5. Replace gears

6. Replace shaft(s)

Problem: Engine idles poorly

Condition Remedy

1. Valve clearance out of adjustment

2. Valve seating poor

3. Valve guides defective

4. Rocker arms - arm shaft worn

5. Magneto defective

6. ECU defective

7. Spark plug fouled - gap too wide

8. Ignition coil defective

9. Idle Step Control (ISC) malfunction

1. Adjust clearance

2. Replace - service seats - valves

3. Replace cylinder head

4. Replace arms - shafts

5. Replace stator coil

6. Replace ECU

7. Adjust gap - replace plug

8. Replace ignition coil

9. Replace ISC

Problem: Engine runs poorly at high speed

Condition Remedy

1. High RPM “cut out” against RPM limiter

2. Valve springs weak

3. Valve timing incorrect

4. Cam - rocker arms - tappets worn

5. Spark plug gap too narrow

6. Ignition coil defective

7. Fuel pump defective

8. Air cleaner element obstructed

9. Fuel hose obstructed

1. Shift into higher gear - decrease speed

2. Replace springs

3. Correct timing - check chain, sprockets, and cam chain ten-

stioner

4. Replace cam - arms - tappets

5. Adjust gap

6. Replace ignition coil

7. Replace fuel pump

8. Clean element

9. Clean or replace hose

Problem: Exhaust smoke dirty or heavy

Condition Remedy

1. Oil (in the engine) overfilled - contaminated

2. Piston rings - cylinder worn

3. Valve guides worn

4. Cylinder wall scored - scuffed

5. Valve stems worn

6. Stem seals defective

1. Drain excess oil - replace oil

2. Replace - service rings - cylinder

3. Replace cylinder head

4. Replace - service cylinder

5. Replace valves

6. Replace seals

Problem: Engine lacks power

Condition Remedy

1. Valve clearance incorrect

2. Valve springs weak

3. Valve timing incorrect

4. Piston ring(s) - cylinder worn

5. Valve seating poor

6. Spark plug fouled

7. Rocker arms - shafts worn

8. Spark plug gap incorrect

9. Air cleaner element obstructed

10. Oil (in the engine) overfilled - contaminated

11. Intake manifold leaking air

12. Cam chain worn

1. Adjust clearance

2. Replace springs

3. Re-time valve gear

4. Replace - service rings - cylinder

5. Replace cylinder head/valves

6. Clean - replace plug

7. Replace arms - shafts

8. Adjust gap - replace plug

9. Clean element

10. Drain excess oil - change oil

11. Tighten - replace manifold

12. Replace cam chain

Problem: Engine overheats

Condition Remedy

1. Carbon deposit (piston crown) excessive

2. Oil low

3. Octane low - gasoline poor

4. Oil pump defective

5. Oil circuit obstructed

7. Intake manifold leaking air

8. Fan malfunctioning

9. Fan switch malfunctioning

10. Radiator fus obstructed

11. Coolant level low

12. Thermostat sticking

1. Clean piston

2. Add oil

3. Drain - replace gasoline

4. Replace pump

5. Clean circuit

7. Tighten - replace manifold

8. Check fan fuse - replace fan

9. Replace fan switch

10. Clean radiator

11. Add coolant

12. Replace thermostat

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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.

Secure the ATV on a support stand to elevate the wheels.

1. Remove the seat and tool kit; then disconnect the

negative battery cable.

2. Remove the left footwell, footrest, and footwell sup-

port assembly; then drain the coolant into a suitable

container.

FI530A

3. From the left side, remove the gear position switch

connector (A) and the speed sensor connector (B).

FI525A

4. Drain the engine oil into a suitable container.

5. Remove the gas tank (see Fuel/Lubrication/Cooling

section); then remove the air inlet tube from the

throttle body.

FI691A

6. Remove the air inlet and outlet ducts from the CVT

housing.

7. Remove the muffler and exhaust pipe. Account for a

grafoil seal on each end of the exhaust pipe.

8. Loosen the clamp securing the air filter housing to the

front air inlet duct; then disconnect the coil connector

and remove the spark plug cap from the spark plug.

FI519A

9. Disconnect the crankcase breather hose from the air

filter housing and remove the air filter housing

assembly.

10. From the top side, remove the engine coolant temper-

ature (ECT) sensor connector (C), fuel injector con-

nector (D), manifold absolute pressure (MAP) sensor

connector (E), idle step control (ISC) connector (F),

and throttle position sensor (TPS) connector (G).

AT THIS POINT

If the technician’s objective is to service Top-Side Com-

ponents, Left-Side Components, or Right-Side Compo-

nents, 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.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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FI522A

11. From the right side, disconnect the stator connector

(H) and crankshaft position sensor connector (I)

from the main harness; then disconnect the positive

cable from the starter motor and the engine ground

cable from the starter mounting flange.

FI523A

FI533A

12. Remove the screws securing throttle arm cover to the

throttle body; then loosen the throttle cable jam-nut

and remove the throttle cable.

FI536A

13. Remove the cap screws securing the exhaust pipe to

the cylinder head; then remove the springs securing

the muffler to the exhaust pipe.

14. Remove coolant hoses (A) and (B) from the water

pump; then remove the upper coolant hose from the

thermostat housing.

FI530B

FI537

15. Remove the cap screws securing the front and rear

drivelines to the output drive flange.

16. Support the engine and remove the two through bolts

securing the engine assembly to the frame; then

move the engine rearward sufficiently to disengage

the front driveline and remove the engine from the

left side.

Top-Side Components

NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to

be addressed and to service only those components.

The technician should use discretion and sound

judgment.

NOTE: The engine/transmission does not have to

removed from the frame for this procedure.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

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Removing Top-Side

Components

A. Cylinder Head Cover/Rocker Arms

B. Cylinder Head/Camshaft

NOTE: Remove the spark plug, timing inspection

plug, and outer magneto cover; then using an appro-

priate wrench, rotate the crankshaft to top-dead-cen-

ter of the compression stroke.



NOTE: Arctic Cat recommends the use of new gas-

kets, lock nuts, and seals and lubricating all internal

components when servicing the engine/transmission.

1. Remove the cap screws securing the two valve

inspection covers. Remove the two covers. Account

for the O-rings.

FI603

NOTE: Keep the mounting hardware with the covers

for assembly purposes.

2. Remove the cylinder head cover cap screws. Note

the rubber washers on the four top-side cap screws;

remove the cylinder head cover. Note the orientation

of the cylinder head plug and remove it. Note the

location of the two alignment pins.

FI606A

MD1354A

3. Remove the cap screw from the tension adjuster;

then using a common screwdriver, relax the cam

chain tension by rotating the adjuster screw clock-

wise until it locks.

FI607A

FI608

5. Bend the washer tabs and remove the two cap screws

securing the sprocket to the camshaft.

FI612

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6. Using an awl, rotate the C-ring in its groove until it is

out of the cylinder head; then remove the C-ring.

FI613

NOTE: Care should be taken not to drop the C-ring

down into the crankcase.

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 cyl-

inder head. Account for an alignment pin.

NOTE: Loop the chain over the cylinder and secure

it to keep it from falling into the crankcase.

FI620

FI617A

8. Remove the cam chain tensioner pivot bolt and

remove the chain tensioner; then remove the two

nuts securing the cylinder head to the cylinder.

FI616

FI617

FI618A

FI619A

9. Remove the four cylinder head cap screws and wash-

ers. 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.

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CD211

10. Remove the cylinder head from the cylinder, remove

the gasket, and account for two alignment pins.

FI623A

11. Remove the cam chain guide.

FI621

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.

FI622A

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.

FI624A

14. Using an awl, remove the piston-pin circlips. Take

care not to drop them into the crankcase.

FI625

15. Using Piston Pin Puller, remove the piston pin.

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.

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MD1219

NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install a connect-

ing rod holder.

Servicing Top-Side

Components



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

VALVE ASSEMBLY

When servicing valve assembly, inspect valve seats,

valve stems, valve faces, and valve stem ends for pits,

burn marks, or other signs of abnormal wear.

NOTE: Whenever a valve is out of tolerance, it must

be replaced.

Cleaning/Inspecting Cylinder Head

Cover

NOTE: If the cylinder head cover cannot be trued,

the cylinder head assembly must be replaced.

1. Wash the cylinder head cover in parts-cleaning solvent.

2. Place the cylinder head cover on the Surface Plate

covered with #400 grit wet-or-dry sandpaper. Using

light pressure, move the cylinder head cover in a fig-

ure 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.

CC130D

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.

CC132D

2. Remove the valve seal and the lower remaining

spring seat. Discard the valve seal.

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.

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.

CAUTION

Do not remove an excessive amount of the sealing sur-

face or damage to the camshaft will result. Always

check camshaft clearance when resurfacing the cylin-

der head cover.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

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CC134D

CC136D

NOTE: The valve seals must be replaced.

3. Remove the valve springs; then invert the cylinder

head and remove the valves.

Measuring Valve Stem Runout

1. Support each valve stem end with the V Blocks; then

check the valve stem runout using a dial indicator.

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 rangesmust be within specifications.

Measuring Valve Face/Seat Width

1. Using a calipers, measure the width of the valve face.

FI367

2. Acceptable width must be at or above 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 out-

side edge of the valve face; then zero the indicator.

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.

CC131D

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3. Push the valve from side to side; then from top to

bottom.

4. Maximum “wobble” deflection must not exceed

specifications.

Measuring Valve Guide

(Inside Diameter)

1. Insert a snap gauge 1/2 way down into each valve

guide bore; then remove the gauge and measure it

with a micrometer.

2. Acceptable inside diameter range must be within

specifications.

3. If a valve guide is out of tolerance, 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 compo-

nents be taken to a qualified machine shop for servicing.

Measuring Rocker Arm

(Inside Diameter)

1. Using a dial calipers, measure the inside diameter of

the rocker arm.

2. Acceptable inside diameter range must be within

specifications.

Measuring Rocker Arm Shaft

(Outside Diameter)

1. Using a micrometer, measure the outside diameter of

the rocker arm shaft.

2. Acceptable outside diameter range must be within

specifications.

Installing Valves

1. Apply grease to the inside surface of the valve seals;

then place a lower spring seat and valve guide seal

over each valve guide.

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.

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.

CC132D

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.

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.

CAUTION

If valves are discolored or pitted or if the seating sur-

face is worn, the valve must be replaced. Do not attempt

to grind the valves or severe engine damage may occur.

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CC400D

2. Remove each ring by working it toward the top of

the piston while rotating it out of the groove.

NOTE: When installing new rings, install as a com-

plete set only.

Cleaning/Inspecting Piston Ring

Grooves

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.

Measuring Piston-Ring End Gap

(Installed)

1. Place each piston ring in the wear portion of the cyl-

inder. 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 specifi-

cations.

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 specifica-

tions, the piston pin must be replaced.

ATV-1070

2. Inspect and measure the connecting rod small end. If

the measurement exceeds specifications, the con-

necting 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.

ATV-1069

Measuring Piston Skirt/Cylinder

Clearance

1. Measure the cylinder front to back in six places.

CC127D

2. Measure the corresponding piston diameter at a point

8 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.

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.

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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.

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.

MD1343A

CYLINDER/CYLINDER HEAD

ASSEMBLY

NOTE: If the cylinder/cylinder head assembly can-

not be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

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 com-

bustion 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 assem-

bly by continuing to move the cylinder head in a fig-

ure eight motion until a uniform bright metallic

finish is attained.

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 between

the head and the straightedge.

3. Maximum distortion must not exceed specifications.

CC141D

Cleaning/Inspecting Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Inspect the cylinder for pitting, scoring, scuffing,

warpage, and corrosion. If marks are found, repair

the surface using a cylinder hone (see Honing Cylin-

der 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 continu-

ing to move the cylinder in a figure eight motion

until a uniform bright metallic finish is attained.

CAUTION

Incorrect installation of the piston rings will result in

engine damage.

CAUTION

The cylinder head studs must be removed for this pro-

cedure.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

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CC129D

Inspecting Cam Chain Guide

1. Inspect cam chain guide for cuts, tears, breaks, or

chips.

2. If the chain guide is damaged, it must be replaced.

Honing Cylinder

1. Using a slide gauge and a dial indicator or a snap

gauge, measure the cylinder bore diameter in three

locations from top to bottom and again from top to

bottom at 90° from the first measurements for a total

of six measurements. The trueness (out-of-round-

ness) is the difference between the highest and low-

est reading. Maximum trueness (out-of-roundness)

must not exceed specifications.

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 pat-

tern, 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.

CC390D

4. If any measurement exceeds the limit, the cylinder

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.

CC283D

2. Rotate the camshaft and note runout; maximum tol-

erance must not exceed specifications.

Measuring Camshaft Lobe Height

1. Using a calipers, measure each cam lobe height.

ATV1013A

2. The lobe heights must be greater than minimum

specifications.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

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Inspecting Camshaft Bearing

Journal

1. Inspect the bearing journal for scoring, seizure

marks, or pitting.

2. If excessive scoring, seizure marks, or pitting is

found, the cylinder head assembly must be replaced.

Measuring Camshaft to Cylinder

Head Clearance

1. Loosen the jam nuts and adjuster screws.

CC005D

2. Place a strip of plasti-gauge in each of the camshaft

lands in the cylinder head.

3. Place the cylinder head cover on the cylinder head

and secure with the cap screws. Tighten securely.

NOTE: Do not rotate the camshaft when measuring

clearance.

4. Remove the cap screws securing the cylinder head

cover to the cylinder; then remove the cylinder head

cover and camshaft.

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 cylinder head cover

clearance.

CC145D

6. If clearance is excessive, measure the journals of the

camshaft.

CC287D

NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still

out of tolerance, replace the cylinder head.

Inspecting Camshaft

Spring/Unloader Pin

1. Inspect the spring and unloader pin for damage.

CF061A

NOTE: With the weight extended, the unloader pin

should be flat-side out; with the weight retracted, the

unloader pin should be round-side out.

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CF060A

2. If damaged, the camshaft must be replaced.

Installing Top-Side

Components

A. Piston

B. Cylinder

1. Lubricate the piston pin, connecting rod, and piston pin

bore with motor oil; then install the piston on the con-

necting rod making sure there is a circlip on each side.

NOTE: The piston should be installed so the IN

points towards the intake.

FI626

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.

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.

GZ142

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.

FI622A

C. Cylinder Head/Camshaft

D. Cylinder Head 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

The cylinder should slide on easily. Do not force the cyl-

inder or damage to the piston, rings, cylinder, or crank-

shaft assembly may occur.

CAUTION

Care should be taken that the bottom of the chain guide

is secured in the crankcase boss.

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FI621

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.

MD1347

7. Install the four cylinder head cap screws with wash-

ers. 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.

8. Install the two lower nuts securing the cylinder head

to the cylinder, one in front and one in rear.

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.

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.

Tighten to 11 ft-lb.

CD383

12. With the alignment pin installed in the camshaft and

the cam lobes directed down (toward the piston),

place the camshaft in position and verify that the tim-

ing mark on the magneto is visible through the

inspection plug and that the timing marks on the

camshaft sprocket are parallel with the cylinder head

cover mating surface.

GZ190C

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.

CD463

CAUTION

Keep tension on the cam chain to avoid damaging the

crankcase boss.

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MD1359

14. Place the C-ring into position in its groove in the cyl-

inder head.

FI615

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 cylinder head cover mating surface. If rotating the

camshaft and sprocket is necessary for alignment, do

not allow the crankshaft to rotate and be sure the

cam lobes end up in the down position.

15. When the camshaft assembly is seated, ensure the

following.

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward the pis-

ton).

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.

16. Place the tab washer onto the sprocket making sure it

covers the pin in the alignment hole.

MD1363

17. Apply red Loctite #271 to the first cap screw secur-

ing the sprocket and tab washer to the camshaft; then

install the cap screw and tab washer. Tighten cap

screw only until snug.

CC404D

FI612

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.

CAUTION

If any of the above factors are not as stated, go back to

step 13 and carefully proceed.

CAUTION

Care must be taken that the tab washer is installed cor-

rectly to cover the alignment hole on the sprocket. If the

alignment pin falls out, severe engine damage will

result.

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MD1137

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 down-

wards.

21. Place the cam chain tensioner assembly and gasket

into the cylinder. Tighten to 10 ft-lb.

22. Using a flat-blade screwdriver, turn the tensioner

screw counterclockwise to apply tension to the cam

chain; then install the cap screw plug and washer and

tighten securely.

FI608

23. Loosen the adjuster screw jam nuts; then loosen the

adjuster screws on the rocker arms in the valve

cover.

24. Apply a thin coat of Three Bond Sealant to the mat-

ing surface of the valve cover; then place the valve

cover into position. Note that the two alignment pins

are properly positioned.

NOTE: At this point, the rocker arms and adjuster

screws must not have pressure on them.

25. Install the four top-side cap screws with rubber

washers; then install the remaining cap screws.

Tighten only until snug.

MD1261

26. In a crisscross pattern starting from the center and

working outward, tighten the cap screws (from step

25) to 8 ft-lb.

27. Adjust valve/tappet clearance (see Periodic Mainte-

nance section).

28. Place the two valve inspection covers with O-rings

into position; then install and tighten the cap screws

to 8 ft-lb.

FI602

29. 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.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

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Removing Left-Side

Components

A. Water Pump

B. Speed Sensor

C. Magneto Cover/Stator Assembly

1. Remove the coolant hose connecting the water pump

to the cylinder; then remove the water pump cover.

FI538

2. Remove the water pump housing assembly noting

the location of the longer cap screw. Account for a

gasket and two alignment pins.

FI539

FI541

3. Remove two cap screws and the oil bolt securing the

oil pressure relief line to the engine. Account for two

crush washers and an O-ring.

FI544

4. Remove the water pump drive gear; then remove the

speed sensor housing assembly. Account for two

alignment pins, a gasket, and two seal washers.

FI543

5. Remove the cap screws securing the magneto cover

to the crankcase. Note the location of the two inter-

nal cap screws and the two longer cap screws.

FI596A

6. Remove the magneto cover and account for two

alignment pins and the gasket.

D. Rotor/Flywheel

E. Starter Clutch/Gear

F. Starter Motor

NOTE: Steps 1-6 in the preceding sub-section must

precede this procedure.

7. Remove the nut securing the rotor/flywheel on the

crankshaft and install the crankshaft protector.

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FI549

8. Using the Magneto Rotor Remover Set, break the

rotor/flywheel loose from the crankshaft; then remove

the puller and crankshaft protector and remove the

rotor/flywheel.

FI550

9. Remove the flywheel key from the crankshaft; then

remove the starter clutch gear.

FI551A

10. Remove starter idler gears and their respective

shafts; then remove the starter motor. Account for an

O-ring on the starter drive housing.

FI555

G. Shift Shaft

H. Drive Gear

NOTE: Steps 1-10 in the preceding sub-sections

must precede this procedure.

11. Remove the shift shaft noting a washer on each end;

then remove the cap screw securing the gear shift

cam plate and remove the plate from the shaft.

FI559

12. Remove the shift detent cam arm and spring.

FI560

13. Remove the snap ring securing the output drive gear

to the output shaft and remove the gear noting that

the hub flange is directed toward the crankcase.

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FI564

FI566

Servicing Left-Side

Components

INSPECTING STARTER

CLUTCH/GEAR

1. Place the starter clutch gear onto the rotor/flywheel

and attempt to rotate the starter clutch gear clock-

wise. It should lock up to the rotor/flywheel. Rotate

the gear counterclockwise and it should turn freely. If

it moves or locks up both ways, the starter clutch

must be replaced.

2. Inspect the starter clutch gear for chipped or missing

teeth or discoloration/scoring of the clutch surface.

Inspect the bearing for loose, worn, or discolored

rollers. If bearing is damaged, it must be replaced.

FI569

3. Inspect the one-way bearing for chipped surfaces,

missing rollers, or discoloration. If any of the above

conditions exist, replace the starter clutch assembly.

FI572

REPLACING STARTER CLUTCH

ASSEMBLY

1. Remove the cap screws securing the one-way clutch

assembly to the flywheel; then remove from the fly-

wheel.

FI570

2. Thoroughly clean the rotor/flywheel; then install the

new one-way clutch and secure with the cap screws

after applying a drop of red Loctite #271 to the

threads. Tighten to 26 ft-lb using a crisscross pattern.

Make sure the one-way bearing is installed with the

notches directed away from the rotor/flywheel.

FI576A

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FI578

REPLACING STARTER GEAR

BEARING

1. Support the starter clutch gear in a press making sure

to support the hub around the entire circumference;

then using a suitable bearing driver, press the bearing

from the gear.

FI583

2. Thoroughly clean the gear hub; then apply a drop of

green Loctite #620 to the bearing outer race and

press into the gear hub until even with the lower

chamfer radius.

FI580

INSPECTING STATOR/MAGNETO

COVER ASSEMBLY

1. Inspect the stator for burned or discolored wiring,

broken or missing hold-down clips, or loose cap

screws.

2. Inspect the bearings in the magneto housing for dis-

coloration, roughness when rotated, and secure fit in

bearing bores.

3. Inspect the oil pressure relief valve for evidence of metal

chips or contamination. Do not disassemble the valve.

FI588

REPLACING STATOR/ CRANKSHAFT

POSITION SENSOR

1. Remove the three cap screws securing the stator coil,

two cap screws securing the crankshaft position sen-

sor, and one cap screw from the harness hold-down.

2. Lift the rubber grommet out of the housing; then

remove the stator coil/crankshaft position sensor.

Account for and note the position of the harness

hold-down under the crankshaft position sensor.

FI590

3. Install the new stator assembly and secure with three

cap screws using a drop of red Loctite #271 on each.

Tighten to 8 ft-lb.

4. Place the stator wire harness hold-down into posi-

tion; then install the crankshaft position sensor and

secure with two cap screws. Tighten securely.

5. Install the upper cable hold-down and secure with a

cap screw. Tighten securely.

FI595A

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REPLACING MAGNETO COVER

BEARINGS

1. Using a suitable press and proper support, press the

bearing from the housing as indicated (one from out-

side and one from inside).

FI593

FI594

2. Clean the bearing bores in the housing and inspect

closely for cracks or shiny areas indicating bearing

movement. Replace the housing if any of the above

are evident.

3. With a drop of red Loctite #271 around the bearing

bore, press a new bearing into the magneto cover

until the bearing is firmly seated in the bearing bore.

Installing Left-Side

Components

A. Starter Clutch/Gear

B. Rotor/Flywheel

1. If removed, place the crankshaft bearing retainer into

position. Apply red Loctite #271 to the three cap

screws. Install and tighten the three cap screws securely.

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.

MD1086

4. Install the shift detent cam arm and spring.

5. Install the gear shift shaft assembly and washer mak-

ing sure to align the alignment marks.

FI559

6. Install starter idler gears (1) and (2).

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FI555A

7. Install the starter clutch gear onto the crankshaft;

then install the rotor/flywheel key in the crankshaft.

FI551A

8. Install the rotor/flywheel and secure with the flange

nut. Tighten to 107 ft-lb.

C. Magneto Cover

D. Water Pump

NOTE: Steps 1-8 in the preceding sub-section must

precede this procedure.

9. Install two alignment pins and place the magneto

cover gasket into position. Install the magneto cover.

Noting the different-lengthed 6 mm cap screws and

the location of the two internal cap screws, tighten

cap screws in a crisscross pattern to 8 ft-lb.

FI596A

10. Install the water pump drive gear and secure with the

nut. Tighten to 28 ft-lb.

FI547

11. Install two alignment pins and a gasket on the mag-

neto cover; then install the water pump housing

assembly. Tighten the cap screws to 8 ft-lb.

FI541A

FI539

12. Install the water pump cover with a new O-ring and

secure with the four cap screws. Tighten to 8 ft-lb.

FI538

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13. Connect the coolant hoses to the water pump and

secure with the hose clamps. Tighten securely.

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.

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

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.

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 align-

ment pins and a gasket.

KC142A

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.

MD1033

4. Remove the movable drive face and spacer. Account

for the movable drive face rollers and outer drive

face cover.

MD1035

MD1034

AT THIS POINT

To service center crankcase components only, proceed

to Removing Right-Side Components.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

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MD1036

5. Using a 6 mm cap screw threaded into the fixed

driven face, spread the driven pulley by turning the

cap screw clockwise; then remove the V-belt.

KC132

6. Remove the fixed drive face.

MD1094

7. Remove the nut holding the driven pulley assembly;

then remove the driven pulley assembly.

MD1068

8. Using an impact screwdriver, remove the three Phil-

lips-head cap screws holding the air intake plate.

Remove the air intake plate.

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.

MD1115

D. Centrifugal Clutch Assembly

E. Oil Pump Drive Gear

F. Oil Pump Driven Gear

G. Oil Pump

NOTE: Steps 1-10 in the preceding sub-section

must precede this procedure.

11. Remove the one-way clutch noting the direction of the

green dot or the word OUTSIDE for installing purposes.

MD1286

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12. Remove the left-hand threaded nut holding the cen-

trifugal clutch assembly.

MD1014

MD1016

13. Remove the cam chain.

MD1335

14. Remove the oil pump drive gear cap screw.

MD1018

15. Remove oil pump drive gear. Account for the pin.

MD1017

16. Remove the snap ring holding the oil pump driven

gear.

MD1019

NOTE: Always use a new snap ring when installing

the oil pump driven gear.

17. Remove oil pump driven gear. Account for the drive

pin and thrust washer.

CAUTION

Care must be taken when removing the nut; it has

“left-hand” threads.

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MD1020

18. Remove three screws holding the oil pump and

remove the oil pump. Account for two alignment pins.

MD1060

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.

ATV1014

INSPECTING CENTRIFUGAL

CLUTCH HOUSING

1. Inspect the clutch housing for burns, marks, scuffs,

cracks, scratches, or uneven wear.

2. If the housing is damaged in any way, the housing

must be replaced.

INSPECTING PRIMARY ONE-WAY

DRIVE

1. Place the one-way clutch onto the clutch shoe assem-

bly with the green dot or the word “OUTSIDE”

directed away from the clutch shoe.

KC330

2. Place the clutch housing onto the clutch

shoe/one-way clutch.

NOTE: It will be necessary to rotate the clutch hous-

ing counterclockwise to properly seat the one-way

clutch.

KC331A

AT THIS POINT

To service clutch components, see Servicing Right-Side

Components sub-section.

AT THIS POINT

To service center crankcase components only, proceed

to Separating Crankcase Halves.

CAUTION

Always replace clutch shoes as a complete set or

severe imbalance could occur.

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3. Check that the clutch shoe can only be rotated coun-

terclockwise in respect to the clutch housing. If the

clutch shoe locks up or turns either direction, the

one-way clutch must be replaced.

KC332A

INSPECTING OIL PUMP

1. Inspect the pump for damage.

2. It is inadvisable to remove the screw securing the

pump halves. If the oil pump is damaged, it must be

replaced.

NOTE: The oil pump is a non-serviceable compo-

nent and must be replaced as a complete assembly.

DRIVEN PULLEY ASSEMBLY

NOTE: The driven pulley assembly is a non-service-

able component and must be replaced as a complete

assembly.

Installing Right-Side

Components

A. Oil Pump

1. 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.

MD1060

2. 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.

MD1020

MD1019

3. Install the cam chain.

NOTE: Keep tension on the cam chain to avoid dam-

aging the crankcase boss.

4. Place the pin into position, install the oil pump drive

gear, and tighten the cap screw (coated with red Loc-

tite #271) to 63 ft-lb.

MD1017

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MD1018

5. 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.

6. Install the one-way clutch making sure that the green dot or

the word OUTSIDE is directed away from the crankcase.

MD1286

B. Clutch Cover

C. Fixed Drive Face

D. Movable Drive Face

NOTE: Steps 1-6 in the preceding sub-section must

precede this procedure.

7. Install two alignment pins and place the clutch cover

gasket into position. Install the clutch cover.

MD1115

8. Tighten the clutch cover cap screws to 8 ft-lb.

MD1117

9. Install the air intake plate. Apply red Loctite #271 to

the threads of the three Phillips-head cap screws;

then install and tighten securely.

MD1342

10. Place the driven pulley assembly into position and

secure with the nut (threads coated with red Loctite

#271). Tighten to 147 ft-lb.

MD1068

KC134

CAUTION

Care must be taken when installing the flange nut; it has

“left-hand” threads.

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11. Slide the fixed drive face assembly onto the front

shaft.

12. 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.

KC137

NOTE: The arrows on the V-belt should point in

direction of engine rotation.

13. 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.

KC127

14. Coat the threads of the nut with red Loctite #271;

then making sure the splines of the clutch shaft pro-

trude through the cover plate, secure with the nut and

tighten to 147 ft-lb.

KC138

KC141

NOTE: At this point, the cap screw can be removed

from the driven pulley face.

15. Rotate the V-belt and drive/driven assemblies until

the V-belt is flush with the top of the driven pulley.

16. 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.

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.



NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to be

addressed and to service only those components. The

technician should use discretion and sound judgment.

Separating Crankcase

Halves

1. Remove the left-side and right-side cap screws

securing the crankcase halves noting the position of

the different-sized cap screws for joining purposes.

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MD1006

2. Using Crankcase Separator/Crankshaft Remover and

tapping lightly with a rubber mallet, separate the

crankcase halves. Account for two alignment pins.

NOTE: To keep the shaft/gear assemblies intact for

identification, tap the shafts toward the left-side

crankcase half when separating the halves.

MD1313

Disassembling Crankcase

Half

NOTE: To aid in installing, it is recommended that

the assemblies be kept together and in order.

NOTE: For steps 1-6, refer to illustration FI639A.

FI639A

1. Remove the secondary driven shaft assembly (A)

noting the location of the front and rear bearing

locating pins and the center bearing locating ring.

FI660A

FI659A

FI661A

2. Remove the reverse idler assembly (B). Account for

and note the location of the inner bushing (1), idler

shaft (2), and outer washer (3).

FI641A

3. Remove the driveshaft (C); then pull the shift fork

locating shaft (D) out of the crankcase locating boss

and allow the shift forks to disengage from the gear

shift shaft (F).

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FI646

FI653A

4. Remove the gear shift shaft (F) noting the inner and

outer washers.

FI650A

5. Remove the countershaft assembly (E) along with

the shift fork assembly.

FI662

6. Remove the crank balancer driven gear (G) and

account for a key; then remove the crankshaft bal-

ancer shaft.

MD1024

7. Using Crankcase Separator/Crankshaft Remover

with the appropriate crankshaft protector, remove the

crankshaft.

MD1330

8. 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.

Servicing Center

Crankcase Components

NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,

replacement is necessary.

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.

AT THIS POINT

To service crankshaft assembly, see Servicing Center

Crankcase Components sub-section.

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SECONDARY GEARS

NOTE: When checking and correcting secondary

gear backlash and tooth contact, the output drive

flange must be secured to the front shaft or false

measurements will occur.

Checking Backlash

NOTE: The rear shaft and bevel gear must be

removed for this procedure. Also, always start with

the original shims on the rear shaft.

1. Place the left-side crankcase cover onto the left-side

crankcase half to prevent runout of the secondary

transmission output shaft.

2. Install the secondary driven output shaft assembly

onto the crankcase.

3. Mount the indicator tip of the dial indicator on the

secondary driven bevel gear (centered on the gear

tooth).

4. While rocking the driven bevel gear back and forth,

note the maximum backlash reading on the gauge.

5. Acceptable backlash range is 0.05-0.33 mm

(0.002-0.013 in.).

Correcting Backlash

NOTE: If backlash measurement is within the

acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing shim, measure it, and install a

new thinner shim.

2. If backlash measurement is more than specified,

remove an existing shim, measure it, and install a

thicker shim.

NOTE: Continue to remove, measure, and install

until backlash measurement is within tolerance. Note

the following chart.

Checking Tooth Contact

NOTE: After correcting backlash of the secondary

driven bevel gear, it is necessary to check tooth con-

tact.

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 revo-

lutions in both directions.

6. Examine the tooth contact pattern in the dye and

compare the pattern to the illustrations.

ATV-0103

ATV-0105

ATV-0104

Correcting Tooth Contact

NOTE: If tooth contact pattern is comparable to the

correct pattern illustration, no correction is neces-

sary.

If tooth contact pattern is comparable to an incorrect pat-

tern, correct tooth contact according to the following

chart.

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.

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

Tooth Contact Shim Correction

Contacts at Top Decrease Shim Thickness

Contacts at Root Increase Shim Thickness

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CRANKSHAFT ASSEMBLY

Measuring Connecting Rod

(Small End Inside Diameter)

NOTE: The crankshaft and connecting rod is a

non-serviceable assembly. If any component is out

of specification, the assembly must be replaced.

1. Insert a snap gauge into the upper connecting rod

small end bore; then remove the gauge and measure

it with micrometer.

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 con-

necting 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.

CC289D

3. Acceptable gap range must be within specifications.

Measuring Crankshaft (Runout)

1. Place the crankshaft on a set of V blocks.

2. Mount a dial indicator and base on the surface plate.

Position the indicator contact at point 1 of the crankshaft.

ATV-1074

3. Zero the indicator and rotate the crankshaft slowly.

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.

CAUTION

After correcting tooth contact, backlash must again be

checked and corrected (if necessary). Continue the cor-

recting backlash/correcting tooth contact procedures

until they are both within tolerance values.

CAUTION

Care should be taken to support the connecting rod

when rotating the crankshaft.

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ATV-1017

2. Acceptable width range must be within specifica-

tions.

COUNTERSHAFT

Disassembling

1. Remove the reverse driven gear dog; then remove

the circlip securing the reverse driven gear.

FI663

FI664

2. Remove the splined washer; then remove the reverse

driven gear along with the bearing and bushing.

FI665

3. Remove the low driven gear washer; then remove the

low driven gear along with the bearing and bushing.

FI666

FI667

4. Remove the splined washer; then remove the circlip

securing the high-low sliding dog. Remove the slid-

ing dog.

FI668

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.

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FI669

5. Remove the circlip securing the high driven gear; then

remove a washer, the high driven gear along with the

bearing and bushing, and remove the high driven washer.

FI670

FI671

Assembling

1. With the high driven washer (1) on the countershaft,

install the high driven gear bushing (3), bearings (2),

and gear (4) on the countershaft; then install the

washers (5) and secure with the snap-ring.

FI671A

FI670

2. Install the high/low shift dog (6) on the countershaft

and secure with snap-ring (7); then install the splined

washer (8).

FI668A

3. Install the low driven bushing (10), bearing (9), and

gear (11) on the countershaft; then install splined

washer (12).

FI667A

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FI666

4. Place the reverse driven bushing (13) onto the shaft;

then install the bearing (14), gear (15), and splined

washer (16). Secure with a snap-ring.

FI665A

FI664

5. Install the reverse dog on the shaft; then place the

shift forks and shift shaft into position.

FI663

FI662

NOTE: The countershaft assembly is now ready to

be installed.

Assembling Crankcase

Half

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.

MD1199

MD1079

2. Install and tighten the output shaft flange nut to 59

ft-lb. Using a punch, peen the nut.

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MD1333

3. Apply a liberal amount of oil to the crankshaft bear-

ing. Using a propane torch, heat the bearing until the

oil begins to smoke; then slide the crankshaft assem-

bly into place.

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 crank balancer

shaft.

5. Install the key in the crank balancer shaft; then install

the gear and aligning the timing marks, slide the gear

into place.

FI658

6. Align the shift cam fork slots with the shift fork shaft

locating boss and with a washer on each end, install

the shift shaft into the crankcase.

FI652A

7. Place the shift forks into position on the assembled

countershaft and install into the crankcase as an

assembly.

FI662

FI653

8. Align the shift forks to allow engagement with the

shift cam; then engage the shift forks and slide the

shift fork shaft into the locating boss in the crankcase.

FI653A

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FI655A

9. Install the input driveshaft.

FI646

10. Install the spacer (1), shaft (2), reverse idler gear, and

washer (3).

FI641A

FI645

11. Install the secondary output driveshaft assembly into

the crankcase half making sure the front and rear

bearing alignment pins are seated in the recesses;

then install the center carrier bearing alignment

C-ring.

FI660A

FI659A

FI661A

Joining Crankcase Halves

1. Verify that the two alignment pins (A) 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.

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FI639B

NOTE: Be sure to apply sealant to the inside radius

of all cap screw locations and the entire surface of

the internal cap screw bosses.

FI639C

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.

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.

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.

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.

Installing

Engine/Transmission

1. From the left side, place the engine into the frame

(rear of engine first) tilting the rear up to allow cylin-

der head to clear frame.

2. With engine moved rearward, engage the splines of the

front driveline into the front output drive yoke; then

move into position and install the two through-bolts.

Secure with lock nuts and tighten to 35 ft-lb.

3. Install the four cap screws securing the rear driveline

to the output drive flange and tighten to 20 ft-lb.

4. Connect coolant hoses (A) and (B) to the water pump

and connect the upper coolant hose to the thermostat

housing. Tighten all clamps securely.

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.

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FI530B

FI537

5. Install the exhaust pipe using a new seal at the cylin-

der head and loosely install the retaining cap screws;

then install the muffler with a new grafoil seal and

secure with two springs. Tighten the exhaust pipe

retainer cap screws to 20 ft-lb.

6. Connect the throttle cable and adjust free-play to

specifications (see Fuel/Lubrication/Cooling sec-

tion); then tighten the jam-nut securely and install

the cover. Tighten the screws securely.

7. Connect the stator connector (H) and crankshaft

position sensor connector (I) to the main harness;

then connect the positive cable to the starter motor

and tighten securely.

FI534A

8. Connect the engine ground cable to the starter

mounting flange and secure with a cap screw tight-

ened to 8 ft-lb.

9. From the top side, install the ECT sensor connector

(C), fuel injector connector (D), MAP sensor connec-

tor (E), ISC connector (F), and the TPS connector (G).

FI522A

10. Place the air filter assembly into position and con-

nect the crankcase breather securing with the clamp,

then connect the front air inlet duct and secure with a

hose clamp.

11. Install the harness connector onto the coil and install

the spark plug cap.

12. Connect the air ducts to the CVT housing and tighten

the clamps securely; then connect the air inlet tube to

the throttle body and secure with the clamps.

13. Install the gas tank (see Fuel/Lubrication/Cooling

section) and connect the negative battery cable; then

install the tool tray.

14. Pour the specified amount of coolant into the radiator

and the specified amount and grade of oil into the

engine.

15. Install the left footwell support assembly, footwell,

and footrest. Tighten all fasteners securely.

16. Install the seat making sure it locks securely in place;

then start the engine and allow to warm up while

checking for leaks.

17. Shut engine off and inspect coolant and oil levels.

Add fluids as required.

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Fuel/Lubrication/Cooling



NOTE: Arctic Cat recommends the use of new gas-

kets, lock nuts, and seals and lubricating all internal

components when servicing the engine/transmission.

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Electronic Fuel Injection

TROUBLESHOOTING

1. Verify that the electric fuel pump is operating by lis-

tening 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 in this section.

2. Check for a flashing EFI icon on the LCD. If EFI is

flashing, see ECU Error Codes in the Electrical Sys-

tem section.

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 contam-

ination. Clean or replace as necessary (see Periodic

Maintenance section).

Throttle Body

REMOVING

1. Remove the heat shields and seat.

2. Disconnect the negative battery cable; then remove

the gas tank (see Gas Tank in this section).

3. Loosen the clamp securing the intake boot to the throttle

body; then loosen the clamp securing the intake boot to

the intake housing and slide the intake housing rearward.

FI691A

4. Disconnect the MAP/IAT sensor connector, ISC con-

nector, and TPS connector; then loosen the clamp

securing the throttle body to the intake manifold boot

and slide the throttle body out.

FI528A

5. Remove the throttle arm cover and loosen the throttle

cable jam nut; then disconnect the throttle cable and

remove the throttle body.

INSTALLING

1. Connect the throttle cable to the throttle arm; then

install the throttle cable housing in the throttle body

and tighten the jam nut. Install the throttle arm cover

and secure with two machine screws.

2. Place the throttle body into the intake manifold boot

and tighten the boot clamp securely.

3. Place the intake housing into the boots and tighten

the boot clamps securely.

4. Install the gas tank; then the heat shields and seat.

Throttle Cable Free-Play

To adjust throttle cable free-play, see Periodic Maintenance.

Description p/n

Oil Pressure Test Kit 0644-495

Tachometer 0644-275

! WARNING

Whenever any maintenance or inspection is performed

on the fuel system during which there may be fuel leak-

age, there should be no welding, smoking, open flames,

etc., in the area.

! WARNING

Gasoline may be under pressure. Place an absorbent

towel under the connector to absorb any gasoline spray

when disconnecting.

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Gas Tank

REMOVING

1. Disconnect the negative battery cable; then remove

the seat and side panels.

2. Remove the cap screws (A) securing the rear of the

front body to the frame; then remove two reinstall-

able rivets (B) securing the gas tank cover to the

body.

KC219A

3. Remove the gas tank cap; then remove the gas tank

cover. Place gas tank cap back on tank.

KC220

4. Remove the cap screw securing the gas tank to the frame

and using a suitable block, support the rear of the tank;

then remove the clamp securing the gasline hose. Discon-

nect the gas line connector from the fuel pump outlet.

KC241A

5. Using a suitable block, hold the front body open and

remove the gas tank to the rear. Account for the heat

shield.

KC260

KC262

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 dam-

aged threads.

! 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.

! WARNING

Gasoline may be under pressure. Place an absorbent

towel under the connector to absorb any gasoline spray

when disconnecting.

! 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.

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INSTALLING

1. Using a block to hold the front body open, place the

gas tank into position in the frame making sure the

heat shield is in position.

KC262

KC252A

2. Using a suitable block, support the rear of the tank

and connect the gasline hose to the gas tank valve

outlet.

KC241A

3. Remove all blocking and secure the gas tank with the

cap screw. Tighten securely; then connect the gasline

connector to the fuel pump outlet.

KC225A

4. Secure the rear of the front body to the frame with

the cap screws (A) and tighten securely; then install

the gas tank cover and secure with the reinstallable

rivets (B).

KC219A

5. Install the side panels and seat making sure it locks

securely in place. connect the negative battery cable

and check for leaks.

Oil Filter/Oil Pump

NOTE: Whenever internal engine components wear

excessively or break and whenever oil is contami-

nated, the oil pump should be replaced. The oil pump

is not a serviceable component.

Testing Oil Pump

Pressure

1. Connect the Tachometer to the engine.

2. Connect the Oil Pressure Test Kit to the oil filter

drain plug.

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KC195A

KC267



NOTE: Some oil seepage may occur when installing

the oil pressure gauge. Wipe up oil residue with a cloth.

3. Warm up the engine to normal operating temperature

(cooling fan cycling); then increase engine RPM to

3000 RPM. The oil pressure must read 0.6-0.7 kg/cm

(8.5-17 psi).

KC268

KC269

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 clogged oil passage, clogged oil filter, or

improper installation of the oil filter.

Liquid Cooling System

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.

RADIATOR

Removing

1. Drain the coolant at the engine.

2. Remove the front rack and body panel (see Steer-

ing/Frame/Controls section).

3. Remove the upper and lower coolant hoses; then

remove the fill hose and air bleed hose.

4. Remove the cap screws securing the radiator to the

frame.

5. Disconnect the fan wiring from the main wiring har-

ness; then remove the radiator/fan assembly and

account for the grommets and collars.

6. Remove the fan/fan shroud assembly from the radiator.

Cleaning and Inspecting



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Flush the radiator with water to remove any contami-

nants.

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.

2. Place the radiator with grommets and collars into

position on the frame; then install the cap screws.

Tighten securely.

3. Install the upper and lower coolant hoses, fill hose,

and air bleed hose; then secure with hose clamps.

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.

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AF734D

4. Install the front body panel and rack (see Steer-

ing/Frame/Controls section).

5. Fill the cooling system with the recommended

amount of antifreeze. Check for leakage.

6. Connect the fan wiring to the main wiring harness.

THERMOSTAT

Removing

1. Drain approximately one quart of coolant from the

cooling system.

2. Remove the two cap screws securing the thermostat

housing to the mounting bracket. Remove the ther-

mostat housing cover and account for an O-ring and

a thermostat.

Inspecting

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

1. Inspect the thermostat for corrosion or spring damage.

2. Using the following procedure, inspect the thermo-

stat for proper operation.

A. Suspend the thermostat in a container filled with

water.

B. Heat the water and monitor the temperature with a

thermometer.

C. The thermostat should start to open at 71-86° C

(160-187° 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.

NOTE: All coolant hoses and clamps should be

replaced every four years or 4000 miles.

Installing

1. Place the thermostat and O-ring into the thermostat

housing; then secure the thermostat housing to the

mounting bracket with the two cap screws.

2. Fill the cooling system to the recommended level

with antifreeze. Check for leakage.

WATER PUMP

NOTE: The water pump is a non-serviceable compo-

nent. It must be replaced as an assembly.

Removing

1. Remove the radiator cap; then remove the water

pump drain and drain the coolant.

FI530A

2. Drain the oil from the engine/transmission.

3. Remove the four torx-head cap screws securing the

front and rear fenders to the footrest; then remove the

four cap screws securing the footrest to the frame.

Remove the footrest.

4. Loosen the hose clamps and slide the clamps away

from the hose ends approximately 2 in.; then remove

the hoses from the water pump.

5. Remove the four cap screws securing the water

pump to the engine; then remove the water pump.

FI538A

Installing

1. Secure the water pump to the engine with the four

cap screws tightened to 8 ft-lb.

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FI538A

2. Connect the coolant hoses to the water pump and

secure with the clamps. Tighten securely.

FI530

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.

Electric Fuel Pump/Fuel

Level Sensor

The electric fuel pump and fuel level sensor are not ser-

viceable components. If either component fails, it must

be replaced.

TESTING

1. Turn the ignition switch ON and listen for a momen-

tary “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.

FI092A

3. Turn the ignition switch to the ON position. The fuel

pressure should build until the pump shuts off. Pres-

sure 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.

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 volt-

age. If battery voltage is indicated and the fuel pump

does not run, replace the pump assembly. If no bat-

tery voltage is indicated, check the ECU and the

vehicle tilt sensor.

REMOVING

1. Disconnect the negative battery cable from the battery.

2. Remove the seat and side heat shields; then remove

the cap screws (A) securing the rear of the front body

to the frame; then remove two reinstallable rivets (B)

securing the gas tank cover to the body.

! 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 electric fuel pump, the following

check should be performed to determine that removal is

necessary.

! WARNING

Gasoline may be under pressure. Place an absorbent

towel under the connector to absorb any gasoline spray

when disconnecting.

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KC219A

3. Remove the gas cap; then remove the tank cover and

install the gas cap back on the tank.

KC220

4. Mark the fuel pump and gas tank for proper orienta-

tion during assembly; then disconnect the fuel

pump/fuel level sender connector.

KC423

5. Disconnect the gas line connector from the fuel

pump outlet.

6. Remove the screws securing the fuel pump to the gas

tank; then make a reference mark on the fuel pump

and tank.

7. Lift out the fuel pump assembly and carefully guide

the pump and float lever through the opening in the

gas tank.

8. Using duct tape or other suitable means, cover the

fuel pump opening.

INSPECTING

1. Inspect the fuel screen and blow clean with low pres-

sure 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).

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).

FI460A

! WARNING

Gasoline may be under pressure. Place an absorbent

towel under the connector to absorb any gasoline spray

when disconnecting.

! 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.

CAUTION

Take care not to damage the float or float arm or

replacement of the entire assembly will be necessary.

AT THIS POINT

If the pump has failed earlier test and must be replaced,

proceed to INSTALLING.

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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 open-

ing; then carefully guide the fuel pump into position

taking care not to damage the float or float lever.

KX190

3. Rotate the fuel pump until the match marks align;

then install the mounting screws and tighten securely

using a crisscross pattern.

NOTE: It is important to install the fuel pump with

the correct orientation to ensure adequate float lever

clearance.

4. Connect the wires and fuel hose; then connect the

negative battery cable and 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 oper-

ation. Check for any fuel leaks.

6. Install the gas tank cover, side heat shields, and seat

making sure the seat locks securely.

Troubleshooting

Problem: Starting impaired

Condition Remedy

1. Gas contaminated 1. Drain gas tank and fill with clean gas

Problem: Idling or low speed impaired

Condition Remedy

1. TPS out of adjustment 1. Adjust TPS

Problem: Medium or high speed impaired

Condition Remedy

1. High RPM “cut out” against RPM limiter 1. Decrease RPM speed

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Electrical System

This section has been organized into sub-sections which

show procedures for the complete servicing of the Arctic

Cat ATV electrical system.

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Electrical Connections

The electrical connections should be checked periodi-

cally for proper function. In case of an electrical failure,

check fuses, connections (for tightness, corrosion, dam-

age), and/or bulbs.

Battery

The battery is located under the seat.

After being in service, batteries require regular cleaning

and recharging in order to deliver peak performance and

maximum service life. The following procedure is rec-

ommended for cleaning and maintaining a sealed battery.

Always read and follow instructions provided with bat-

tery chargers and battery products.

NOTE: Refer to all warnings and cautions provided

with the battery or battery maintainer/charger.

Loss of battery charge may be caused by ambient temper-

ature, ignition OFF current draw, corroded terminals, self

discharge, frequent start/stops, and short engine run

times. Frequent winch usage, snowplowing, extended

low RPM operation, short trips, and high amperage

accessory usage are also reasons for battery discharge.

Maintenance Charging

NOTE: Arctic Cat recommends the use of the CTEK

Multi US 800 or the CTEK Multi US 3300 for battery

maintenance charging. Maintenance charging is

required on all batteries not used for more than two

weeks or as required by battery drain.

800E

1. When charging a battery in the vehicle, be sure the

ignition switch is in the OFF position.

2. Clean the battery terminals with a solution of baking

soda and water.

NOTE: The sealing strip should NOT be removed

and NO fluid should be added.

3. Be sure the charger and battery are in a well-venti-

lated area. Be sure the charger is unplugged from the

110-volt electrical outlet.

4. Connect the red terminal lead from the charger to the

positive terminal of the battery; then connect the

black terminal lead of the charger to the negative ter-

minal of the battery.



NOTE: Optional battery charging adapters are avail-

able from your authorized Arctic Cat dealer to connect

directly to your vehicle from the recommended char-

gers to simplify the maintenance charging process.

Check with your authorized Arctic Cat dealer for proper

installation of these charging adapter connectors.

5. Plug the battery charger into a 110-volt electrical

outlet.

6. If using the CTEK Multi US 800, there are no further

buttons to push. If using the CTEK Multi US 3300,

press the Mode button (A) at the left of the charger

until the Maintenance Charge Icon (B) at the bottom

illuminates. The Normal Charge Indicator (C) should

illuminate on the upper portion of the battery charger.



NOTE: The maintainer/charger will charge the battery

to 95% capacity at which time the Maintenance Charge

Indicator (D) will illuminate and the maintainer/charger

will change to pulse/float maintenance. If the battery

falls below 12.9 DC volts, the charger will automatically

start again at the first step of the charge sequence.

Description p/n

Fluke Model 73 Multimeter 0644-191

Fluke Model 77 Multimeter 0644-559

MaxiClips 0744-041

Peak Voltage Reading Adapter 0644-307

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3300A

NOTE: Not using a battery charger with the proper

float maintenance will damage the battery if con-

nected over extended periods.

Charging

NOTE: Arctic Cat recommends the use of the CTEK

Multi US 800 or the CTEK Multi US 3300 for battery

maintenance charging.

1. Be sure the battery and terminals have been cleaned

with a baking soda and water solution.

NOTE: The sealing strip should NOT be removed

and NO fluid should be added.

2. Be sure the charger and battery are in a well-venti-

lated area. Be sure the charger is unplugged from the

110-volt electrical outlet.

3. Connect the red terminal lead from the charger to the

positive terminal of the battery; then connect the

black terminal lead of the charger to the negative ter-

minal of the battery.

4. Plug the charger into a 110-volt electrical outlet.

5. By pushing the Mode button (A) on the left side of

the charger, select the Normal Charge Icon (E). The

Normal Charge Indicator (C) should illuminate on

the upper left portion of the charger.

6. The battery will charge to 95% of its capacity at

which time the Maintenance Charge Indicator (D)

will illuminate.

NOTE: For optimal charge and performance, leave

the charger connected to the battery for a minimum 1

hour after the Maintenance Charge Indicator (D) illu-

minates. If the battery becomes hot to the touch, stop

charging. Resume after it has cooled.

7. Once the battery has reached full charge, unplug the

charger from the 110-volt electrical outlet.



NOTE: If, after charging, the battery does not perform

to operator expectations, bring the battery to an autho-

rized Arctic Cat dealer for further troubleshooting.

RPM Limiter

NOTE: The ATV is equipped with an 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.

Testing Electrical

Components

All of the electrical tests should be made using the Fluke

Model 73 Multimeter or Fluke Model 77 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 trou-

bleshooting a specific component, always verify first that

the fuse(s) are good, that the bulb(s) are good, that the

connections are clean and tight, that the battery is fully

charged, and that all appropriate switches are activated.

NOTE: For absolute accuracy, all tests should be

made at room temperature of 68° F.

Accessory

Receptacle/Connector

NOTE: This test procedure is for either the recepta-

cle or the connector.

VOLTAGE

1. Turn the ignition switch to the ON position; then set

the meter selector to the DC Voltage position.

2. Connect the red tester lead to the red wire; then con-

nect the black tester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery, fuse, receptacle, connector, or

the main wiring harness.

Brakelight Switch

(Pressure)

The brakelight switch is located on the top of the auxil-

iary brake master cylinder and is pressure activated by

the hand brake or the auxiliary brake pedal. This switch

also activates the start-in-gear (SIG) relay in the power

distribution module (PDM).



NOTE: The ignition switch must be in the ON position.

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VOLTAGE

(Wiring Harness Side)

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester to the brown/black wire; then

connect the black tester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery, fuse, switch, or the main wiring

harness.

NOTE: If the meter shows battery voltage, the main

wiring harness is good; proceed to test the

switch/component or connector.

RESISTANCE (Switch)

1. Remove the spade connectors from the brake switch.

2. Set the meter selector to the OHMS position.

3. Connect the red tester lead to one switch terminal;

then connect the black tester lead to the other switch

terminal.

KC274

4. When the brake pedal is depressed, the meter must

show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, replace the switch.

Engine Coolant

Temperature (ECT)

Sensor

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 con-

tainer or inaccurate readings will occur. Use wire

holders to suspend the sensor and thermometer.

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 approxi-

mately 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 along the right-side frame tube.

KC270A

NOTE: The ignition switch must be in the ON posi-

tion.

VOLTAGE (Main Harness Connector

to Fan Motor)

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the orange wire; then

connect the black tester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery, fuse, motor, or the main wiring

harness.

NOTE: If the meter shows battery voltage, the main

wiring harness is good. The connector should be

checked for resistance.

! WARNING

Wear insulated gloves and safety glasses. Heated oil

can cause severe burns.

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RESISTANCE (Fan Motor

Connector)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the red wire; then con-

nect the black tester lead to the black wire.

3. The meter must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, troubleshoot or replace the switch/component,

the connector, or the switch wiring harness.



NOTE: To determine if the fan motor is good, connect

the blue 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.

Fuse Block/Power

Distribution Module

The fuses are located in a power distribution module in

front of the steering post. In addition, there is a 30 amp

fuse on the starter relay under the seat next to the battery.

If there is any type of electrical system failure, always

check the fuses first.

NOTE: To remove a fuse, compress the locking tabs

on either side of the fuse case and lift out.

2411-565

KC210A

NOTE: The ignition switch must be in the LIGHTS

position.

1. Remove all fuses from the distribution module.

2. Set the meter selector to the DC Voltage position.

3. Connect the black tester lead to ground.

4. Using the red tester lead, contact each end of the fuse

holder connector terminals individually.

5. The meter must show battery voltage from one side

of the connector terminal ends.

NOTE: Battery voltage will be indicated from only

one side of the fuse holder connector terminal; the

other side will show no voltage.

NOTE: When testing the HI fuse holder, the head-

light dimmer switch must be in the HI position; when

testing the LIGHTS fuse holder, the headlight dimmer

switch can be in either position.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery, switches, distribution module,

or the main wiring harness.

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.

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.

RELAYS

The relays are identical plug-in type located on the power

distribution module. Relay function can be checked by

switching relay positions. The relays are interchangeable.

NOTE: The module and wiring harness are not a

serviceable component and must be replaced as an

assembly.

Ignition Coil

The ignition coil is on the electrical panel under the radi-

ator/electrical access panel.

! WARNING

Care should be taken to keep clear of the fan blades.

CAUTION

Always replace a blown fuse with a fuse of the same

type and rating.

CAUTION

Always disconnect the battery when performing resis-

tance tests to avoid damaging the multimeter.

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RESISTANCE

NOTE: For these tests, the meter selector should be

set to the OHMS position and the primary wire should

be disconnected.

Primary Winding

1. Connect the red tester lead to either terminal; then

connect the black tester lead to the other terminal.

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. Connect the black tester lead to ground.

3. The meter reading must be within specification.

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.

AR603D

2. The meter reading must be within specification.

NOTE: If the meter does not read as specified,

replace the spark plug cap.

Primary Voltage - ECU

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.

Speed Sensor

1. Set the meter selector to the DC Voltage position.

2. With appropriate needle adapters on the meter leads,

connect the red tester lead to the voltage lead (V);

then connect the black tester lead to the ground lead

(G).

KC248A

3. Turn the ignition switch to the ON position.

4. The meter must show greater than 5.0 volts.

5. Leave the black tester lead connected; then connect

the red tester lead to the signal lead pin (S).

6. Slowly move the ATV forward or backward; the

meter must show 0 and 6 volts alternately.

NOTE: If the sensor tests are within specifications,

the speedometer must be replaced (see Steer-

ing/Frame/Controls section).

To replace a speed sensor, use the following procedure.

1. Disconnect the three-wire connector from the speed

sensor; then remove the cap screw securing the sen-

sor to the sensor housing.

2. Remove the sensor from the sensor housing account-

ing 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 cap screw (threads

coated with blue Loctite #242). Tighten securely.

CD071

CAUTION

Always disconnect the battery when performing resis-

tance tests to avoid damaging the multimeter.

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Ignition Switch

The ignition switch harness connects to the switch with a

three-pin connector. To access the connector, remove the

access panel in front of the handlebar.

KC339D

VOLTAGE

NOTE: Perform this test on the main harness con-

nector.

1. Set the meter selector to the DC Voltage position.

2. Connect the red meter lead to the red/white wire;

then connect the black meter lead to ground.

3. Meter must show battery voltage.

NOTE: If the meter shows no battery voltage, trou-

bleshoot the battery or the main wiring harness.

RESISTANCE

NOTE: Perform this test on the switch harness

using the following procedure.

KC276A

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 B; then connect the

other tester lead to pin A.

4. The meter must show less than 1 ohm.

5. Turn the ignition switch to the LIGHTS position.

The meter must show less than 1 ohm.

6. Leaving the tester lead on pin B, connect the other

tester lead to pin C.

7. The meter must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, replace the switch.

Handlebar Control

Switches

The connectors are located on the right side of the ATV

next to the PDM. To access the connector, the electrical

cover must be removed.

NOTE: These tests should be made on the switch

side of the connector.

RESISTANCE (HI Beam)

1. Set the meter selector to the OHMS position.

2. Connect one tester lead to the brown/black wire; then

connect the other tester lead to the lavender wire.

3. With the dimmer switch in the HI position, the meter

must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, replace the switch.

RESISTANCE (LO Beam)

1. Connect one tester lead to the brown/black wire; then

connect the other tester lead to the white wire.

2. With the dimmer switch in the LO position, the

meter must show an open circuit.

NOTE: If the meter reads resistance, replace the

switch.

RESISTANCE (Emergency Stop)

1. Set the meter selector to the OHMS position.

2. Connect the one lead to the brown/lavender wire;

then connect the other tester lead to the black/white

wire.

3. With the switch in the OFF position, the meter must

show an open circuit.

4. With the switch in the RUN position, the meter must

show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resis-

tance, replace the switch.

RESISTANCE (Reverse Override)

1. Set the meter selector to the OHMS position.

2. Connect one tester lead to one lavender/red wire;

then connect the other tester wire to the green/red

wire. The meter must show less than 1 ohm.

3. Depress and hold the reverse override button. The

meter must show an open circuit.

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NOTE: If the meter does not show as specified,

replace the switch.

Front Drive Selector

Switch

The connector is the snap-lock one in front of the steering

post. To access the connector, the electric cover must be

removed.

NOTE: Resistance tests should be made with the

connector disconnected and on the selector-side of

the connector.

RESISTANCE

1. Set the meter selector to the OHMS position.

2. Connect the one tester lead to the white/blue wire;

then connect the other tester lead to the black wire.

3. With the selector switch in the 2WD position, the

meter must show an open circuit.

4. With the selector switch in the 4WD position, the

meter must show less than 1 ohm.

NOTE: If the meter does not show as specified,

replace the front drive selector switch.

VOLTAGE

NOTE: The battery must be connected when per-

forming 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 white/blue wire on

the harness side of the connector.

4. Turn the ignition switch to the RUN position.

5. The meter must show battery voltage.

NOTE: If the meter shows other than specified,

check the harness, connector, 30 amp fuse, and bat-

tery connections.

Front Drive Selector

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.

VOLTAGE

1. Select the 2WD position on the front drive selector

switch; then disconnect the connector on the actuator

wiring harness.

2. With the ignition switch in the OFF position, connect

the black tester lead to the black wire in the supply

harness; then connect the red tester lead to either

orange wire in the supply harness.

3. Turn the ignition switch to the ON position. The

meter must show 12 DC volts.

4. Connect the red tester lead to the second orange wire

in the supply harness. The meter must show 12 DC

volts.

5. Connect the red tester lead to the white/green wire in

the supply harness. The meter must show 12 DC

volts.

6. Select the 4WD position on the front drive selector

switch; then connect the red tester lead to the

white/blue wire in the supply harness. The meter

must show 0 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 Drive System).

Gear Position Switch

The gear position switch is located on the engine/trans-

mission next to the shift arm.

FI525B

To troubleshoot the switch, use the following procedure.

1. Disconnect the gear position switch connector; then

using a multimeter, test the switch in each position as

follows. Resistance must be less than 1 ohm for all tests.

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KC410A

A. Neutral (N) Pins 3 to 4

B. Reverse (R) Pins 3 to 4 and 3 to 2

C. High (H) Pins 3 to 4 and 3 to 1

D. Low (L) Pins 3 to 1

2. Connect the harness to the gear position switch.

Stator Coil

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 nega-

tive battery post.

3. With the engine running at a constant 3000 RPM

(with the headlights on), the meter must show

14-15.5 DC volts.

NOTE: If voltage is lower than specified, test charg-

ing coil - no load.

VOLTAGE (Charging Coil - No Load)

The connector is the black three-pin one on the right side

of the engine just above the starter motor.

NOTE: Test the 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.

NOTE: If both charging coil tests failed, check all

connections, etc., and test again. If no voltage is

present, replace the stator assembly.

RESISTANCE (Charging Coil)

1. Set the meter selector to OHMS position.

2. Test between the three black wires for a total of three

tests.

3. The meter reading must be within specification.

RESISTANCE (Crankshaft Position

Sensor)

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/white wire;

then connect the black tester lead to the blue/yellow

wire. The meter reading must be within specifica-

tion.

PEAK VOLTAGE

NOTE: All of the peak voltage tests should be made

using the Fluke Model 73 Multimeter or Fluke Model

77 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 this

test.

Crankshaft Position Sensor

1. Set the meter selector to the AC Voltage position.

Connect the red tester lead to the green/white wire; then

connect the black tester lead to the blue/yellow wire.

3. Crank the engine over using the electric starter.

4. The meter reading must be within specification.

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 ter-

minal; then connect the black tester lead to the starter

cable connection on the starter relay. The meter must

show battery voltage.

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 multi-

meter. The multimeter should drop to 0 volts, a

“click” should be heard from the relay, and the starter

motor should run.

CAUTION

Do not run the engine at high RPM for more than 10 sec-

onds.

CAUTION

Do not run the engine at high RPM for more than 10 sec-

onds.

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NOTE: If a “click” is heard and any voltage is indi-

cated by the multimeter, replace the starter relay. If no

“click” is heard and the multimeter continues to indi-

cate battery voltage, test the neutral start relay.

Starter Motor

NOTE: The starter is a non-serviceable component.

If the following test does not result as specified, the

starter must be replaced.

TESTING VOLTAGE

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 posi-

tion, the emergency stop switch in the RUN position,

and the shift lever in the NEUTRAL position.

1. Set the meter selector to the DC Voltage position.

2. Connect the red tester lead to the starter terminal;

then connect the black tester lead to ground.

3. With the starter button depressed, the meter must

show approximately 10.0 DC volts and the starter

motor should operate.

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

ground connections, starter motor lead, battery volt-

age (at the battery), starter relay, or the neutral start

relay.

REMOVING

1. Disconnect the battery.

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

an O-ring.

INSTALLING

1. 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 making sure the engine

ground is secured by the rear cap screws. Tighten to

8 ft-lb.

KC201A

2. Secure the positive cable to the starter with the nut.

Tighten to 8 ft-lb.

3. Connect the battery.

Electronic Control Unit

(ECU)

The electronic control unit (ECU) is located above the

radiator under the radiator/electrical access panel.

NOTE: The ECU is not a serviceable component. If

the unit is defective, it must be replaced.

The ECU is rarely the cause for electrical problems; how-

ever, if the ECU is suspected, substitute another ECU of

the same part number to verify the suspected one is

defective.

Diagnostic Trouble Codes (DTC) can be cleared by fol-

lowing the procedures located in the Diagnostic Trouble

Codes (DTC) sub-section in this section.

Regulator/Rectifier

The regulator/rectifier is located under the front rack and

front fenders above the oil cooler.

TESTING

1. Start engine and warm up to normal operating tem-

peratures; 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.

CAUTION

Always disconnect the negative battery cable from the

battery first; then disconnect the positive cable.

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3. Start the engine and slowly increase RPM. The volt-

age should increase with the engine RPM to a maxi-

mum of 15.5 DC volts.



NOTE: If voltage rises above 15.5 DC volts, the regula-

tor is faulty or a battery connection is loose or corroded.

Clean and tighten battery connections or replace the

regulator/rectifier. If voltage does not rise, check Voltage

(Charging Coil - No Load) in this section. If charging coil

voltage is normal, replace the regulator/rectifier.

Lights

HEADLIGHTS - RUNNING LIGHTS

The connectors are the two 4-pin ones snapped onto the

front body/rack support. To release the connectors from

the frame, press the release tab with a small screwdriver.

KC224

KC223

Voltage (Headlights)

NOTE: Perform this test on the main harness side of

the connectors. Also, the ignition switch must be in

the LIGHTS position.

1. Set the meter selector to the DC Voltage position.

2. Connect the black tester lead to the black wire; then

connect the red tester lead to the white wire.

3. With the dimmer switch in the LO position, the

meter must show battery voltage.

4. Remove the red tester lead from the white wire and

connect to the lavender wire.

5. With the dimmer switch in the HI position, the meter

must show battery voltage.

NOTE: If battery voltage is not shown in any test,

inspect the fuses, battery, main wiring harness, con-

nectors, or the left handlebar switch.

Voltage (Running Lights)

1. Release the wire connector from the frame; then

release and separate the connectors.

NOTE: Perform this test on the wiring harness side

of the connectors.

2. Connect the black tester lead of the meter to the black

wire; then with the tester in the DC Volts position,

connect the red tester lead to the brown/black wire.

3. Turn the ignition switch to the LIGHTS position.

The meter must show battery voltage.

NOTE: If the meter does not show voltage, inspect

the LIGHTS fuse, battery connections, or trouble-

shoot the main wiring harness.

TAILLIGHTS - BRAKELIGHTS

Voltage (Taillights)

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 black tester lead to the black wire; then

connect the red tester lead to the brown/blue wire.

3. The meter must show battery voltage.

NOTE: If the meter does not show voltage, inspect

fuses, wiring harness, connectors, and switches.

Voltage (Brakelights)

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.

1. Set the meter selector to the DC Voltage position.

2. Connect the black tester lead to the black wire; then

connect the red tester lead to the green/yellow wire.

3. The meter must show battery voltage.



NOTE: If the meter does not show voltage, inspect

bulb, fuses, wiring harness, connectors, and switches.

BACK-UP LIGHTS

The connectors are located on the rear frame supports

attached by a metal tab. They may be released from the

frame by depressing the release with a small screwdriver.

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KC279

KC280

Voltage

1. Release the wire connectors from the frame; then

disconnect the connectors.

NOTE: Perform this test on the main harness side of

the connectors.

2. Connect the black tester lead to the brown/lavender

wire; then connect the red tester lead to the laven-

der/red wire.

3. Set the tester to DC VOLTS; then turn the ignition

switch to the ON position and move the shift lever to

the R (reverse) position. The meter must show bat-

tery voltage.

NOTE: If the meter does not show battery voltage,

use the following procedure to troubleshoot.

4. Remove the black tester lead from the brown/laven-

der wire and connect to a suitable ground.

A. If the meter shows battery voltage, troubleshoot

the gear shift position switch connector or the

gear shift position switch.

B. If the meter does not show battery voltage, inspect

the LIGHTS fuse, ignition switch, or the main

wiring harness.

Ignition Timing

The ignition timing cannot be adjusted; however, verifying

ignition timing can aid in troubleshooting other compo-

nents. To verify engine timing, see Periodic Maintenance.

Tilt Sensor

SUPPLY VOLTAGE

1. Disconnect the three-wire connector from the sensor;

then select DC Voltage on the multimeter and con-

nect the red tester lead to the (C) pin and the black

tester lead to the (A) pin.

CD706A

2. Turn the ignition switch to the ON position. The

multimeter should read approximately 5 DC volts. If

correct voltage is not indicated, check the 30-amp

main and 10-amp ignition fuses, wiring harness, or

the ignition switch.

3. Remove the red tester lead and connect to the (B)

pin. The multimeter should read approximately 0.5

DC volts. If the specified voltage is not indicated,

check wire connections at the ECU or substitute

another ECU to verify the test.

CD706B

OUTPUT VOLTAGE

NOTE: Needle adapters or a “break-out” harness

will be required on the multimeter leads as the follow-

ing tests are made with the sensor connected.

! WARNING

Incorrect installation of the tilt sensor could cause sud-

den 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.

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1. Connect the three-wire plug to the sensor; then

remove the mounting screws securing the sensor to

the frame.

KC339E

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 pink/black wire

(A); then turn the ignition switch ON and observe the

meter. The meter should read 0.3-1.5 DC volts.

KC416A

4. Tilt the sensor 60° or more to the left and right

observing the meter. The meter should read 3.0-7.0

DC volts after approximately one second in the tilted

position. If the meter readings are not as specified,

the tilt sensor is defective.

KC414A

KC416B

Throttle Position Sensor

(TPS)

INSPECTING

1. Remove the left-side engine cover; then disconnect

the three-wire TPS connector plug.

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 B and the red

tester lead to terminal A. Turn the ignition switch to the

ON position. The meter should read approximately 5.0

DC volts.

PR538A

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NOTE: If the meter does not read as specified,

check for poor connections at the ECU or open/bro-

ken wires in the wiring harness.

4. Turn the ignition switch to the OFF position.

5. Select the OHMS position on the meter; then per-

form the following resistance tests on the TPS.

A. Pin (B) to ground - infinity (open circuit).

B. Pin (A) to pin (B) - approximately 1.22k ohms

(throttle closed).

C. Pin (A) to pin (B) - approximately 4.5k ohms

(throttle full-open).

D. Pin (A) to pin (C) - approximately 5.5k ohms.

PR535A

NOTE: If any meter reading is not as specified,

replace or adjust the TPS (see INSTALLING/ADJUST-

ING in this sub-section).

6. Connect the positive lead to the battery; then connect

the negative lead.

7. 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.

PR546A

8. Select the DC Voltage position on the meter and turn

the ignition switch to the ON position. The meter

should read approximately 4.5 DC volt with the

throttle closed and approximately 1.5 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).

9. Verify all malfunction codes are closed after servic-

ing is complete (see Diagnostic Trouble Codes

(DTC) in this section).

REMOVING

1. Remove the left-side engine cover; then disconnect

the three-wire TPS connector plug.

PR544

2. Remove the screw securing the TPS to the throttle

body and remove the TPS.

INSTALLING/ADJUSTING

1. Place the TPS into position on the throttle body and

secure with the screw. Do not tighten at this time.

2. Connect the TPS Multi-Analyzer Harness connector

#8 to the TPS; then connect the harness to the TPS

Analyzer Tool.

FI672

CAUTION

Always make sure the ignition switch is in the OFF posi-

tion before disconnecting the ECU.

CAUTION

Always make sure the ignition switch is in the OFF posi-

tion before disconnecting the ECU.

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3. Using a multimeter, connect the black tester lead to

the black socket (GND) on the analyzer and the red

tester lead to the white socket (VAR); then select the

Voltage position.

FI673A

4. Adjust the TPS until a reading of 0.68 DC volts is

obtained; then tighten the screw securely. Open and

close the throttle and determine the reading returns to

0.68 DC volts. Readjust as necessary.

FI674

5. Disconnect the harness from the analyzer; then dis-

connect the harness from the TPS and reconnect the

TPS main harness connector.

6. Tighten the mounting screws securely.

Diagnostic Trouble

Codes (DTC)

If an EFI or related chassis component fails or an

out-of-tolerance signal is detected by the ECU, a diag-

nostic trouble code (DTC) will be generated in the ECU

and displayed on the LCD. For the first thirty seconds,

the LCD will go blank and the DTC will be displayed

alternately with a wrench icon or malfunction indicator

light (MIL). After thirty seconds, the digital display will

return to normal; however, the MIL and DTC will con-

tinue to flash. On models equipped with the analog

gauge, the needle will swing full-scale for thirty seconds;

then return to normal with the MIL and DTC continuing

to flash.

Code List

NOTE: Each of the following numerical codes will

have a one-letter prefix of C or P. A “C” prefix denotes

a chassis malfunction and a “P” prefix denotes a

power train malfunction.

NOTE: Normal malfunction codes are cleared from

the LCD when the component is replaced or the mal-

function is corrected; however, intermittent codes

must be cleared as noted in the code chart.

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Gauge DTC Wrench Icon Status ECU PIN Input/

Output High/Low Variable Description

C0063(1) D2 I V Tilt Sensor Circuit High

C0064(1) ON D2 I V Tilt Sensor Circuit Low/SG/Open

P0107 ON F2 I V MAP Sensor Circuit Low/SG/Open

P0108 ON F2 I V MAP Sensor Circuit High/SP

P0112 ON F3 I V Intake Air Temp Sensor Circuit Low/SG

P0113 ON F3 I V Intake Air Temp Sensor Circuit High/Open

P0114(1) OFF F3 I V Intake Air Temp Sensor Circuit Intermittent

P0116 ON F4 I V Engine Coolant Temp Sensor Circuit Range/Performance

P0117 ON F4 I V Engine Coolant Temp Sensor Circuit Low/SG

P0118 ON F4 I V Engine Coolant Temp Sensor Circuit High/Open/SP

P0119(1) OFF F4 I V Engine Coolant Temp Sensor Circuit Intermittent

P0121 G3 I V Throttle Position Sensor Range/Performance

P0122 ON G3 I V Throttle Position Sensor Circuit Low/SG

P0123 ON G3 I V Throttle Position Sensor Circuit High

P0219 N/A N/A N/A Engine Over-Speed Condition

P0231 ON J1 O L Fuel Pump Relay Circuit Low/SG/Open

P0232 J1 O L Fuel Pump Relay Circuit High

P0233(1) J1 O L Fuel Pump Relay Circuit

P0261(2) ON L4 O L Rear Cylinder Injector Circuit Low/SG

P0262(2) ON L4 O L Rear Cylinder Injector Circuit High

P0263(2) ON L4 O L Rear Cylinder Injector Balance/Open

P0264(2) ON K4 O L Front Cylinder Injector Circuit Low/SG

P0265(2) ON K4 O L Front Cylinder Injector Circuit High

P0266(2) ON K4 O L Front Cylinder Injector Balance/Open

P0336(1) ON D1/E1 I V Crankshaft Angle Sensor Synchronization

P0337(1) ON D1/E1 I V Crankshaft Angle Sensor Circuit/SG

P0339(1) ON D1/E1 I V Crankshaft Angle Sensor Intermittent/Erratic

P0480 K2 O L Fan Relay Control Circuit

P0484 K2 O L Fan Relay Control Circuit High

P0485 ON K2 O L Fan Relay Control Circuit Low/SG/Open

P0500 Gauge Direct Error-Code N/A N/A N/A Vehicle Speed-Sensor

P0508 ON C4/D3/D4/E4 I/O V Idle Air Control System Circuit Low/SG

P0509 ON C4/D4 I/O V Idle Air Control System Circuit High/Open

P0562 L1 I H System Voltage Low

P0563 L1 I H System Voltage High

P0601 N/A N/A N/A ECU Memory Check-Sum Error

P0615(1) L3 O L Starter Relay Circuit

P0616 ON L3 O L Starter Relay Circuit Low

P0617 L3 O L Starter Relay Circuit High

P0630 ON N/A N/A N/A VIN Not Programmed or Incompatible

P0635 Gauge Direct Error-Code N/A N/A N/A Power-Steering Controller Circuit

P0642 A1 O H Sensor Power Circuit Low

P0643 ON A1 O H Sensor Power Circuit High

P0856 Gauge Direct Error-Code N/A N/A N/A Traction Controller Circuit

P2300(2) ON M1 O L Rear Ignition Coil Primary Circuit Low/SG/Open

P2301(2) ON M1 O L Rear Ignition Coil Primary Circuit High

P2303(2) ON M2 O L Front Ignition Coil Primary Circuit Low/Open

P2304(2) ON M2 O L Front Ignition Coil Primary Circuit High

P2531 A4 I H Ignition Switch Circuit Low

P2532 A4 I H Ignition Switch Circuit High

U0155 B1/C1 I/O H/L LCD Gauge Communication Lost

“FUEL OFF” Gauge Direct Error-Code N/A N/A Tilt Sensor Activation Operator-Code

High = Signal Level is too High (Possible Short-to-Battery (+)) Low = Signal Level is too Low (Possible Short-to-Ground or Short-to-Chassis)

SG = Possible Short-to-Ground or Short-to-Chassis SP = Possible Short-to-Power or Short-to-Battery

Open = Open-Circuit (Possible Broken-Wire or No-Connection)

(1): These codes cleared by one complete power-cycle only (key-off, power-latch, key-on):

C0063, C0064, P0114, P0119, P0233, P0336, P0337, P0339, P0615

(2): These codes cleared by one complete starting-cycle only (key-off, power-latch, key-on, start, key-off, power-latch, key-on):

C0261, P0262, P0263, P0264, P0265, P0266, P2300, P2301, P2303, P2304

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Troubleshooting

Problem: Spark absent or weak

Condition Remedy

1. Ignition coil defective

2. Spark plug defective

3. Alternator defective

4. ECU defective

5. Pick-up coil defective

1. Replace ignition coil

2. Replace plug

3. Replace stator coil

4. Replace ECU

5. Replace stator coil

Problem: Spark plug fouled with carbon

Condition Remedy

1. Gasoline incorrect

2. Air cleaner element dirty

3. Spark plug incorrect (too cold)

4. Valve seals cracked - missing

5. Oil rings worn - broken

1. Change to correct gasoline

2. Clean element

3. Replace plug

4. Replace seals

5. Replace rings

Problem: Spark plug electrodes overheat or burn

Condition Remedy

1. Spark plug incorrect (too hot)

2. Engine overheats

3. Spark plug loose

1. Replace plug

2. Service cooling system

3. Tighten plug

Problem: Alternator does not charge

Condition Remedy

1. Stator wires/connections shorted - loose - open

2. Stator coils shorted - grounded - open

3. Regulator/rectifier defective

1. Repair - replace - tighten stator wires

2. Replace stator coils

3. Replace regulator/rectifier

Problem: Alternator charges, but charging rate is below the specification

Condition Remedy

1. Stator wires shorted - open - loose (at terminals)

2. Stator coils grounded - open

3. Regulator/rectifier defective

4. Battery defective

1. Repair - tighten Stator wires

2. Replace stator coils

3. Replace regulator/rectifier

4. Replace battery

Problem: Alternator overcharges

Condition Remedy

1. Battery shorted

2. Regulator/rectifier damaged - defective

3. Regulator/rectifier poorly grounded

1. Replace battery

2. Replace regulator/rectifier

3. Clean - tighten ground connection

Problem: Charging unstable

Condition Remedy

1. Stator wire intermittently shorting

2. Alternator internally shorted

3. Regulator/rectifier defective

1. Replace stator wire

2. Replace stator coil

3. Replace regulator/rectifier

Problem: Starter button inoperative

Condition Remedy

1. Battery charge low

2. Switch contacts defective

3. Starter motor defective

4. Starter relay defective

5. Emergency stop - ignition switch off

6. Wiring connections loose - disconnected

1. Charge - replace battery

2. Replace switch

3. Replace starter motor

4. Replace relay

5. Turn on switches

6. Connect - tighten - repair connections

Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)

Condition Remedy

1. Charging rate too low - too high

2. Battery run-down - damaged

3. Electrolyte contaminated

1. Repair charging system

2. Replace battery

3. Replace battery

Problem: Battery discharges too rapidly

Condition Remedy

1. Electrolyte contaminated

2. Charging system not charging

3. Battery overcharged - damaged

4. Battery short-circuited

1. Replace battery

2. Check alternator - regulator/rectifier - circuit connections

3. Replace battery - correct charging system

4. Replace battery

Problem: Battery polarity reversed

Condition Remedy

1. Battery incorrectly connected 1. Reverse connections - replace battery - repair damage

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Drive System

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.

The “1” or “3.1” on the lower-right corner indicates a

3.1:1 gear set ratio (11:34 teeth).

SPECIAL TOOLS

A number of special tools must be available to the techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Front Drive Actuator

NOTE: The actuator is not a serviceable compo-

nent. If it is defective, it must be replaced.

NOTE: The actuator will operate only when the igni-

tion 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 “whir-

ring” sound can be heard each time the front drive selec-

tor switch is shifted. If no sound is heard, see Electrical

System. If the actuator runs constantly or makes squeal-

ing or grinding sounds, the actuator must be replaced.

REMOVING

1. Disconnect the connector on the actuator harness.

2. Remove the mounting cap screw from the driveshaft

side of the actuator.

KC293A

3. Remove the mounting cap screw from below the

actuator on the suspension side.

KC294A

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.

KC295A

INSTALLING

1. Lubricate the O-ring on the actuator; then ensure that

all mounting surfaces are clean and free of debris.

2. Align the actuator with the selector shaft and slide it

forward onto the shaft taking care to engage the cap

screw in the slot of the front mounting tab.

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.)

Description p/n

Backlash Gauge Tool 0544-010

CV Boot Clamp Tool 0444-120

Gear Case Seal Installer Tool 0444-224

Internal Hex Socket 0444-104

Pinion Gear/Shaft Removal Tool 0444-127

Slide Hammer Kit 0444-225

Multi-Seal Remover 0644-180

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AG925

3. While holding the actuator firmly forward, tighten

the front cap screw to hold the actuator in place; then

install but do not tighten the two remaining cap

screws.

KC295A

4. Loosen the front cap screw; then tighten the cap

screw on the driveshaft side.

AG926

NOTE: It is important to tighten this cap screw while

the others are loose to ensure proper seating of the

actuator.

5. Tighten the remaining cap screws; then connect the

electrical plug to the main harness.

6. Turn the ignition switch to the ON position and

check the operation by shifting the selector switch

several times.

7. Secure the wiring harness to the frame with a nylon

cable tie.

Front Differential

REMOVING DIFFERENTIAL

1. Secure the ATV on a support stand to elevate the

wheels.

2. Remove the drain plug and drain the gear lubricant

into a drain pan; then reinstall the plug and tighten to

45 in.-lb.

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.

6. Release the brake lever lock.

7. Remove the upper and lower ball joint cap screws

taking care not to strip the threads.

AF628D

8. Pull the steering knuckle away from the axle taking

care not to damage the seals as the axle clears the

knuckle.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

CAUTION

Apply pressure to hold the ball joint firmly in the knuckle

or the threads will be stripped when the retaining cap

screws are removed.

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KC314

9. Support the axle to not allow it to drop or hang.

10. Pull out on the axle until completely extended; then

push it back in approximately one half inch and pull

out sharply. Repeat until axle spline dislodges from

the gear case.

KC425A

NOTE: In some instances it may be necessary to

use a pry-bar between the gear case housing and

axle coupler shoulder to dislodge the splines.

KC426A

11. Remove the cap screws from the drive coupler

flange; then remove the upper and lower mounting

cap screws and remove the differential from the

frame.

KC291A

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 dis-

cretion and sound judgment.

1. Remove the cap screws securing the front drive actu-

ator and remove the actuator.

CD102

2. Remove the cap screws securing the pinion housing;

then 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.

CD103

CAUTION

The axle must be supported. If the axle is allowed to

drop or hang, damage to the inner CV joint may occur.

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CD106

3. Using a side-cutter, remove the boot clamps; then

remove the boots and splined drive from the input

shaft.

4. Remove the input shaft from the pinion housing.

CD107

5. Using the Multi-Seal Remover, remove the input

shaft seal. Account for a spacer.

AF982

6. Remove the snap ring securing the input shaft bear-

ing; then place the pinion housing in a press and

remove the bearing.

AF983

AF984

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.

AF993

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AF994

2. Install the input shaft seal making sure it is flush with

the edge of the housing.

3. Lubricate the input shaft splines with High-Perfor-

mance #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.

KX221

KX222

4. Install the input shaft into the housing; then install

the front boot and secure with an appropriate boot

clamp and the rear boot with an appropriate boot

clamp.

CD112

5. Using a new O-ring lubricated with grease, install

the front drive actuator and secure with the cap

screws.

6. Place the pinion housing with new gasket onto the

gear case housing; then secure with the existing cap

screws. Tighten to 18 ft-lb.

CD103

Disassembling Pinion Gear

NOTE: This procedure can be performed on a rear

gear case.

1. Remove the cap screws securing the pinion housing;

then remove the housing and account for a gasket.

Account for the coupler, fork, and spring.

KX209

2. Remove the cap screws securing the gear case cover.

Account for and make note of the ID tag location for

assembling purposes.

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KX173

3. Using a plastic mallet, tap lightly to remove the dif-

ferential cover. Account for an O-ring and a shim.

NOTE: If the cover is difficult to remove, pry on the

cover in more than one recessed location.

GC063

4. 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.

KX179

KX181

5. Unstake the lock collar; then using the 48 mm Inter-

nal Hex Socket, remove the lock collar securing the

pinion gear assembly.

NOTE: On a front differential, the lock collar has

right-hand threads. On a rear gear case, the lock col-

lar has left-hand threads.

CC875

CC876

6. Using the Pinion Gear/Shaft Removal Tool and a

hammer, remove the pinion gear from the gear case

housing.

CAUTION

Failure to completely remove the staked material from

the lock collar will result in the destruction of the

threads in the gear case housing.

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CC878

7. Secure the pinion gear in a bearing puller; then

remove the pinion bearing using a press. Account for

a collar and a bearing.

CC879

NOTE: If gears are being replaced, use the existing

shims.

NOTE: If the gear case housing is being replaced,

proceed to the following Shimming Procedure/Shim

Selection sub-section.

Shimming Procedure/Shim

Selection

It is very important to adjust bevel gears for the proper

running tolerances. Gear life and gear noise are greatly

affected by these tolerances; therefore, it is very important

to properly adjust any gear set prior to final assembly.

The following procedure can be used on both front differ-

ential or rear drive gear case.

NOTE: All bearings must be installed in the gear

case and the pinion properly installed before pro-

ceeding.

Backlash

NOTE: Always set backlash prior to any other shim-

ming.

1. Install the existing shim or a 0.051-0.055-in. shim on

the gear case side of the ring gear assembly.

GC031A

2. Install the ring gear with shim in the gear case; then

while holding the pinion stationary, rock the ring

gear forward and back to determine if any backlash

exists. If no backlash exists, install a thicker shim

and recheck.

GC059A

3. Install the bearing flange onto the gear case cover

making sure the alignment/locating pin engages the

locating hole in the cover; then make sure the bear-

ing flange is completely seated in the cover.

4. Install the existing shim or a 0.063 in. shim on the

cover side of the ring gear; then place the assembled

gear case cover onto the gear case and secure with

three cap screws. Tighten evenly using a crisscross

pattern.

GC059B

Shims

p/n mm in.

0402-405 1.3 0.051

0402-406 1.4 0.055

0402-407 1.5 0.059

0402-408 1.6 0.063

0402-409 1.7 0.067

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5. Place the Backlash Gauge Tool into the splines of the

ring gear and install a dial indicator making sure it

contacts the gauge at a 90° angle and on the index

mark.

GC070

GC072A

6. Zero the dial indicator; then while holding the pinion

stationary, rock the ring gear assembly forward and

back and record the backlash. Backlash must be

0.011-0.015 in. If backlash is within specifications,

proceed to Ring Gear End-Play. If backlash is not

within specifications, increase shim thickness to

increase backlash or decrease shim thickness to

decrease backlash.

NOTE: Higher backlash settings usually result in

quieter gear operation.

GC071A

Ring Gear End-Play

After correcting backlash, ring gear end-play can be

adjusted. To adjust end-play, use the following proce-

dure.

1. Secure the gear case in a holding fixture with the

cover side up; then install a dial indicator contacting

the ring gear axle flange.

GC065

2. Zero the dial indicator; then push the ring gear

toward the dial indicator and release. End-play

should be 0.004-0.008 in.

3. To increase end-play, decrease the shim thickness.

To decrease end-play, increase the shim thickness.



NOTE: Once proper backlash and end play are estab-

lished, the gear case can be assembled (see Assem-

bling Differential Assembly in this sub-section).

CC888

RING GEAR/THRUST BUTTON

Removing

Remove the thrust button from the gear case cover

(left-hand threads). Account for a shim.

Inspecting

1. Inspect the ring gear for excessive wear or discolor-

ation.

2. Inspect the thrust button for excessive wear or dis-

coloration.

3. Inspect the bearings for discoloration, roughness, or

excessive wear.

Installing/Shimming

NOTE: Ring gear end-play must be adjusted prior to

selecting shim for the thrust button.

1. Install the thrust button with shim into the gear case

cover and tighten securely (left-hand threads).

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GC057A

2. Place the ring gear with selected shim into the cover

and measure the ring gear to thrust button clearance

with a thickness gauge. Clearance should be

0.002-0.004 in.

GC058A

3. If clearance is as specified, remove the ring gear and

thrust button; then place a drop of red Loctite #271

on the threads and tighten to 8 ft-lb (left-hand

threads).

4. If clearance is not as specified, repeat steps 1 and 2

using thicker (clearance too great) or thinner (clear-

ance too small) until correct specification is reached.

Assembling Differential Assembly

1. With the pinion gear and new bearings installed,

place the selected (backlash) shim on the gear case

side of the ring gear with the chamfered side toward

the ring gear; then install into gear case/differential

housing.

GC031A

GC059

2. Place the selected (end-play) shim, chamfered side

toward the gear, onto the cover side of the ring gear.

GC059B

NOTE: The spider and ring gear assembly must be

replaced as a complete unit.

3. Making sure the O-ring is properly positioned on the

differential housing cover assembly, install the cover

with existing cap screws (coated with green Loctite

#609). Account for the ID tag. Tighten the cap

screws evenly to 18 ft-lb.

NOTE: Grease can be applied to the O-ring for ease

of assembling.

4. Install the shift fork shaft w/spring into the housing

making sure the shaft O-ring is positioned to the

inside.

CC892

5. 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 (425).

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CC893

6. Place the input shaft assembly onto the gear case

housing; then secure with the existing cap screws.

Tighten to 18 ft-lb.

CD110

Removing Needle Bearing

NOTE: Removing the needle bearing is rarely nec-

essary. Avoid removing the needle bearing unless the

bearing is clearly damaged.

NOTE: This procedure can be performed on a rear

gear case.

1. Place a 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.

CC885

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.

CC887

Installing Needle Bearing

1. Apply green Loctite #609 to the outside of a new

bearing; then place the new bearing into the 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.

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GC045A

3. Install the pinion shaft and secure with a new 48 mm

lock collar. Tighten to 125 ft-lb.

CC890

4. Place a punch on the edge of the lock collar in the oil

gallery area; then using a hammer, stake the lock col-

lar to ensure that the collar will remain securely

tightened.

CC891

5. Install the pinion 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.

GC066

2. Using a press, remove the bearing.

CC900

3. Using a press, install the new bearing into the hous-

ing.

CC901

NOTE: Prior to installing the seal, apply High Perfor-

mance #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.

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GC060

5. Repeat steps 1-4 for the opposite side.

INSTALLING DIFFERENTIAL

1. Align the input flange with the front output flange;

then place the differential into position on the frame

and install the cap screws and nuts. Tighten to 38

ft-lb.

KC291A

2. Install the cap screws securing the flange couplers

together and tighten to 20 ft-lb.

AG925

3. Install the front axles (see Drive Axles in this sec-

tion).

AF610D

AF897D

4. Install the wheels and tighten to 40 ft-lb.

5. 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.

6. Remove the ATV from the support stand.

Drive Axles

REMOVING REAR DRIVE AXLE

1. Secure the ATV on a support stand to elevate the

wheels.

2. Pump up the hand brake; then engage the brake lever

lock.

3. Remove the rear wheels.

4. Remove the cotter pins securing the hex nuts; then

remove the hex nuts. Release the brake lever lock.

5. Remove the cap screw and lock nut securing the

knuckle to the upper A-arm. Discard the lock nut.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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100

KC284

NOTE: Never reuse a lock nut. Once a lock nut has

been removed, it must be replaced with a new lock

nut.

6. While holding the drive axle stationary, pull the top

of the knuckle out and down until it is free of the

drive axle.

KC285

7. Place a drain pan under the ATV to contain any oil

leakage; then pull out sharply on the axle to dislodge

the splines from the gear case. Remove the axle.

REMOVING FRONT DRIVE AXLE

NOTE: For removing a front drive axle, see Front

Differential in this section.

CLEANING AND INSPECTING

NOTE: Always clean and inspect the drive axle com-

ponents to determine if any service or replacement is

necessary.

1. Using a clean towel, wipe away any oil or grease

from the axle components.

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

NOTE: To disassemble/assemble axles, refer to

appropriate boot kit instructions.

INSTALLING REAR DRIVE AXLE

1. Slide the drive axle into place in the gear case.

NOTE: To assure proper seating of the axle, give it a

light pull; the axle should remain “clipped” in place.

2. Swing the knuckle up and onto the drive axle; then

place the knuckle into place in the upper A-arm.

Secure the knuckle to the A-arm with a cap screw

and a new lock nut. Tighten to 35 ft-lb.

3. Place the hub into position on the axle followed by a

hex nuts. Tighten the hex nuts finger-tight at this

time.

4. Pump up the hand brake lever; then engage the brake

lever lock.

5. Tighten the hub hex nuts (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.

6. Install the wheel. Tighten to 40 ft-lb.

7. 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 tight-

ened to 35 ft-lb.

2. Slide the hub w/brake disc into position in the steer-

ing knuckle followed by a washer and hex nut.

Tighten finger-tight at this time.

3. 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.

4. Tighten the hub hex nut (from step 2) 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.

KC305

5. Install the wheel and tighten to 40 ft-lb.

6. Remove the ATV from the support stand and release

the brake lever lock.

7. Check the front differential oil level and add oil as

necessary.

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CF113A

Rear Gear Case

REMOVING

1. Remove both of the rear drive axles (see Drive Axles

in this section).

2. Remove the four cap screws securing the engine out-

put shaft to the rear gear case input flange.

KC169

3. 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.

KC288A

INSTALLING

1. Slide the gear case into position through the left side

of the frame; then secure it to the frame with cap

screws and lock nuts. Tighten to 38 ft-lb.

2. Secure the engine output flange to the rear gear case

input flange with four cap screws and lock nuts.

Tighten to 20 ft-lb.

3. Install the rear drive axles (see Drive Axles in this

section).

Hub

REMOVING

1. Secure the ATV on a support stand to elevate the

wheel; then remove the wheel.

2. Remove the cotter pin from the nut.

NOTE: During assembly, new cotter pins should be

installed.

3. Remove the flange nut securing the hub.

4. Remove the brake caliper.

KC283

5. Remove the hub assembly.

6. Remove the four cap screws securing the brake disc.

CLEANING AND INSPECTING



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.

INSTALLING

1. Secure the brake disc to the hub with the four cap screws

coated with blue Loctite #243. Tighten to 15 ft-lb.

AT THIS POINT

For servicing the input shaft, pinion gear, needle bear-

ing, thrust button, and axle seal, see Front Differential in

this section.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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102

2. Apply grease to the splines in the hub.

3. Install the hub assembly onto the shaft.

4. Secure the hub assembly with the nut. Tighten only

until snug.

5. Secure the brake caliper to the knuckle with the two

cap screws. Tighten the caliper to 20 ft-lb.

KC283

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.

KC305

7. Install the wheel and tighten to 40 ft-lb.

8. Remove the ATV from the support stand.

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.

AF637D

2. Place an absorbent towel around the connection to

absorb brake fluid. Remove the banjo-fitting bolt

from the master cylinder. Account for two crush

washers and a banjo-fitting bolt.

3. Remove the clamp screws securing the brake hous-

ing to the handlebar, then remove the assembly from

the handlebar.

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 and bolt for cracks and dete-

rioration and the condition of the fittings (threaded

and compression).

INSTALLING

1. Position the brake housing on the handlebar. Secure

with clamp screws; then tighten securely.

2. Using two new crush washers, connect the banjo-fit-

ting to the master cylinder; then secure with the

banjo-fitting bolt. Tighten to 20 ft-lb.

3. Bleed the brake system (see Periodic Maintenance).

Hydraulic Brake Caliper

REMOVING/DISASSEMBLING

1. Secure the ATV on a support stand to elevate the

wheel; then remove the wheel.

CAUTION

Brake fluid is highly corrosive. Do not spill brake fluid

on any surface of the ATV.

! WARNING

Arctic Cat recommends that only authorized Arctic Cat

ATV dealers perform hydraulic brake service. Failure to

properly repair brake systems can result in loss of con-

trol causing severe injury or death.

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103

2. Drain the brake fluid from the caliper, hose, and mas-

ter cylinder through the bleed screw by pumping the

brake lever/pedal.

PR235

NOTE: Whenever brake components are removed,

disassembled, or repaired where brake fluid is

exposed to air, drain all fluid and replace with new

DOT 4 brake fluid from an unopened container. Brake

fluid readily absorbs moisture from the air signifi-

cantly lowering the boiling point. This increases the

chance of vapor lock reducing braking power and

increasing stopping distance.

3. Remove the brake hose from the caliper and close

the bleed screw; then remove the caliper.

4. Compress the caliper holder against the caliper

(opposite the O-ring side) and remove the outer

brake pad; then remove the inner brake pad.

NOTE: If brake pads are to be returned to service,

do not allow brake fluid to contaminate them.

PR237A

PR238

5. Remove the caliper holder from the caliper and dis-

card the O-ring.

PR239B

NOTE: The O-ring is used for shipping purposes

and provides no function in operation.

6. Cover the piston end of the housing with a shop

towel; then keeping fingers clear of piston travel,

apply compressed air to the fluid port to blow the

piston free of the housing. Account for two seal

rings in the housing.

PR713A

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

! WARNING

Never let brake fluid contact the eyes. Damage to the

eyes will occur. Always wear appropriate protective

safety goggles and latex gloves when handling brake

fluid.

CAUTION

Brake fluid is highly corrosive. Do not spill brake fluid

on any surface of the ATV and do not reuse brake fluid.

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104

PR715

7. Using an appropriate seal removal tool, carefully

remove the seals from the brake caliper housing; then

remove four O-rings from the brake caliper housing

noting the location of the different sized O-rings. Dis-

card all seals, O-rings, and crush washers.

CLEANING AND INSPECTING

1. Clean all caliper components (except the brake pads)

with DOT 4 brake fluid. Do not wipe dry.

2. Inspect the brake pads for damage and excessive

wear.

NOTE: For measuring brake pads, see Periodic

Maintenance.

3. Inspect the brake caliper housings for scoring in the

piston bores, chipped seal ring grooves, or signs of

corrosion or discoloration.

4. Inspect the piston surface for scoring, discoloration,

or evidence of binding or galling.

5. Inspect the caliper holder for wear or bending.

ASSEMBLING/INSTALLING

1. Install new seals into the brake caliper housing and

apply a liberal amount of DOT 4 brake fluid to the

cylinder bore of the housing, seals, and brake piston.

PR715

PR717A

2. Press the piston into the caliper housing using hand

pressure only. Completely seat the piston; then wipe

off any excessive brake fluid.

PR711A

PR712

3. Apply high-temperature silicone grease (supplied

with the O-ring kit) to the inside of the caliper holder

bores and O-rings; then install the four O-rings into

the caliper.

PR719C

4. Install the caliper onto the caliper holder making sure

the caliper and holder are correctly oriented.

! WARNING

Make sure to hold the towel firmly in place or the piston

could be ejected from the housing causing injury.

CAUTION

Make sure the seals are properly in place and did not

twist or roll during installation.

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105

NOTE: It is very important to apply silicone grease

to the O-rings and caliper bores prior to assembly.

PR239C

5. Making sure brake fluid does not contact the brake

pads, compress the caliper holder toward the caliper

and install the inner brake pad; then install the outer

pad.

PR238

PR239

6. Place the brake caliper assembly into position and

secure with new “patch-lock” cap screws. Tighten

the caliper to 20 ft-lb.

7. Place a new crush washer on each side of the brake

hose fitting and install it on the caliper. Tighten to 20

ft-lb.

8. Fill the reservoir; then bleed the brake system (see

Periodic Maintenance).

9. Install the wheel. Tighten to 40 ft-lb.

10. Remove the ATV from the support stand and verify

brake operation.

Troubleshooting Drive

System

CAUTION

If brake pads become contaminated with brake fluid, they

must be thoroughly cleaned with brake cleaning solvent

or replaced with new pads. Failure to do so will result in

reduced braking and premature brake pad failure.

! WARNING

Never use brake fluid from an open container or reuse

brake fluid. Moisture-contaminated brake fluid could

cause vapor build-up (expansion) during hard braking

resulting in greatly increased stopping distance or loss

of control leading to injury or death.

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 Remedy

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

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

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106

Troubleshooting Brake

System

Problem: Braking poor

Condition Remedy

1. Pad worn

2. Pedal free-play excessive

3. Brake fluid leaking

4. Hydraulic system spongy

5. Master cylinder/brake cylinder seal worn

1. Replace pads

2. Replace pads

3. Repair - replace hydraulic system component(s)

4. Bleed hydraulic system - correct or repair leaks

5. Replace master cylinder

Problem: Brake lever travel excessive

Condition Remedy

1. Hydraulic system entrapped air

2. Brake fluid low

3. Brake fluid incorrect

4. Piston seal - cup worn

1. Bleed hydraulic system

2. Add fluid to proper level

3. Drain system - replace with correct fluid

4. Replace master cylinder

Problem: Brake fluid leaking

Condition Remedy

1. Connection joints loose

2. Hose cracked

3. Piston seal worn

1. Tighten joint

2. Replace hose

3. Replace brake caliper

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107

Suspension

The following suspension system components should be

inspected periodically to ensure proper operation.

A. Shock absorber rods not bent, pitted, or damaged.

B. Rubber damper not cracked, broken, or missing.

C. Shock absorber body not damaged, punctured, or

leaking.

D. Shock absorber eyelets not broken, bent, or

cracked.

E. Shock absorber eyelet bushings not worn, deterio-

rated, cracked, or missing.

F. Shock absorber spring not broken or sagging.

Shock Absorbers

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels and to release load on the suspension.

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.

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.

NOTE: The shock absorbers are not serviceable

components. If leaking, dented, or there are missing

or broken parts, the shock absorber assembly must

be replaced.

INSTALLING

1. Place bushings and sleeves (where appropriate) into

shock eyelet; then install shock with cap screws and

nuts. Tighten all nuts to 35 ft-lb.

2. Remove the ATV from the support stand.

Front A-Arms

REMOVING

1. Secure the ATV on a support stand to elevate the

front wheels; then remove the wheels.

2. Remove the cotter pin from the nut. Discard the cot-

ter pin.

3. Remove the nut securing the hub.

4. Remove the brake caliper. Account for two cap

screws.

KC187A

5. Remove the hub assembly.

6. Remove the cap screws securing the ball joints to the

knuckle.

KC313A

7. Tap the ball joints out of the knuckle; then free the

knuckle from the axle and swing out of the way.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

CAUTION

Additional support stands are necessary to support the

rear axle when the shock absorbers are removed or

damage may occur.

CAUTION

Do not tighten the nuts beyond the 35 ft-lb specification

or the shock eyelet or mount WILL be damaged.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

CAUTION

Support the knuckle when removing the cap screws or

damage to the threads will occur.

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108

KC297

8. Remove the lower shock absorber eyelet from the

upper A-arm.

9. Remove the cap screws securing the A-arms to the

frame.

10. Remove the circlip from the ball joint; then remove

the ball joint from the A-arm.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-

essary.

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 bush-

ings.

4. Inspect the ball joint mounting holes for cracks or

damage.

5. Inspect the frame mounts for signs of damage, wear,

or weldment damage.

INSTALLING

1. Apply green Loctite #609 to the entire outside diam-

eter of the ball joint; then install the ball joint into the

A-arm and secure with the circlip.

2. Install the A-arm assemblies into the frame mounts

and secure with the cap screws. Only finger-tighten

at this time.

3. Secure the lower eyelet of the shock absorber to the

upper A-arm. Tighten nut to 35 ft-lb.

4. Secure the A-arm assemblies to the frame mounts

(from step 2). Tighten the cap screws to 35 ft-lb.

5. Install the knuckle assembly onto the ball joints and

secure with cap screws. Tighten to 35 ft-lb.

6. Apply grease to the hub and drive axle splines; then

install the hub assembly onto the drive axle.

7. Secure the hub assembly with the nut. Tighten only

until snug.

8. Secure the brake caliper to the knuckle with the two

“patch-lock” cap screws. Tighten to 20 ft-lb.

9. Secure the hub nut (from step 7) to the shaft/axle.

Tighten to 200 ft-lb.

10. Install a new cotter pin and spread the pin to secure

the nut.

11. Install the wheel and tighten to 40 ft-lb.

12. Remove the ATV from the support stand.

Rear A-Arms

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels.

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 caliper to hang from

the 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.

KC0100

7. Slide the hub out of the knuckle and set aside.

8. 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.

9. Remove the cap screws and lock nuts securing the

A-arms to the frame; then remove the A-arms.

CAUTION

Do not tighten the nut beyond the 35 ft-lb specification

or the shock eyelet or mount WILL be damaged.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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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 nec-

essary.

1. Clean all A-arm components using a pressure

washer.

2. Inspect the A-arm for bends, cracks, and worn bush-

ings.

3. Inspect the frame mounts for signs of damage, wear,

or weldment damage.

INSTALLING

1. Install the A-arm assemblies into the frame mounts

and secure with the cap screws and new lock nuts.

Only finger-tighten at this time.

2. Slide the knuckle onto the drive axle and into posi-

tion on the A-arms; then secure the knuckle to the

A-arms with cap screws and new lock nuts. Tighten

to 35 ft-lb.

3. Tighten the hardware securing the A-arms to the

frame mounts (from step 1) to 35 ft-lb.

4. Apply grease on the drive axle splines; then install

the hub assembly onto the drive axle.

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.

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.

8. Install a new cotter pin and spread the pin to secure

the nut.

9. Secure the shock absorber to the frame with a cap

screw and new lock nut. Tighten to 35 ft-lb.

10. Secure the shock absorber to the lower A-arm with a

cap screw and new lock nut. Tighten to 35 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.

13. Remove the ATV from the support stand.

Wheels and Tires

TIRE SIZE

The ATV is equipped with low-pressure tubeless tires of

the size and type listed in the General Information sec-

tion. Do not under any circumstances substitute tires of a

different type or size.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 27.6 kPa

(4.0 psi).

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels.

2. Remove the wheels.

NOTE: Keep left-side and right-side wheels sepa-

rated 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 nec-

essary.

1. Clean the wheels and hubs using a pressure washer.

2. Inspect each wheel for cracks, dents, or bends.

3. Inspect each tire for cuts, wear, missing lugs, and

leaks.

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).

AF612D

! WARNING

Use only Arctic Cat approved tires when replacing tires.

Failure to do so could result in unstable ATV operation.

! 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 war-

ranty.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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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.

NOTE: If repair is needed, follow the instructions

found on the tire repair kit or remove the wheel and

have it repaired professionally.

NOTE: Be sure all tires are the specified size and

have identical tread pattern.

3. Check the front wheel toe-in and toe-out and adjust

as necessary (see Steering/Frame/Controls section).

4. Test drive the ATV on a dry, level surface and note

any pulling to the left or right during acceleration,

deceleration, and braking.

NOTE: If pulling is noted, measure the circumfer-

ence 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 Periodic Maintenance sec-

tion).

5. Increase the air pressure in the tires with the smallest

circumference measurement until all tires are equal

in circumference.

6. Repeat steps 4-5 as necessary to ensure proper han-

dling.

Troubleshooting

! WARNING

Do not operate the ATV if tire damage exists.

Problem: Suspension too soft

Condition Remedy

1. Spring(s) weak

2. Shock absorber damaged

3. Shock absorber preload too low

1. Replace spring(s)

2. Replace shock absorber

3. Adjust shock absorber preload

Problem: Suspension too stiff

Condition Remedy

1. A-arm-related bushings worn

2. Shock absorber preload too high

1. Replace bushing

2. Adjust shock absorber preload

Problem: Suspension noisy

Condition Remedy

1. Cap screws (suspension system) loose

2. A-arm-related bushings worn

1. Tighten cap screws

2. Replace bushings

Problem: Rear wheel oscillation

Condition Remedy

1. Rear wheel hub bearings worn - loose

2. Tires defective - incorrect

3. Wheel rim distorted

4. Wheel hub cap screws loose

5. Auxiliary brake adjusted incorrectly

6. Rear suspension arm-related bushing worn

7. Rear shock absorber damaged

8. Rear suspension arm nut loose

1. Replace bearings

2. Replace tires

3. Replace rim

4. Tighten cap screws

5. Adjust brake

6. Replace bushing

7. Replace shock absorber

8. Tighten nut

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Steering/Frame/Controls

The following steering components should be inspected

periodically to ensure safe and proper operation.

A. Handlebar grips not worn, broken, or loose.

B. Handlebar not bent, cracked, and has equal and

complete full-left and full-right capability.

C. Steering post bearing assembly/bearing housing

not broken, worn, or binding.

D. Ball joints not worn, cracked, or damaged.

E. Tie rods not bent or cracked.

F. Knuckles not worn, cracked, or damaged.

G. Cotter pins not damaged or missing.

Steering Post/Tie Rods

REMOVING

1. Remove the front body panel/fender (see Front Body

Panel/Fender in this section).

2. Remove the steering post cover; then remove the cap

screws securing the handlebar caps and move the handle-

bar out of the way. Account for the two handlebar caps.

KC0058

3. Remove the cap screws securing the upper steering

post to the frame. Account for the housing cap, outer

housing, and inner housing.

KC307A

4. Remove the cotter pins from the inner tie rod ends;

then remove the nuts and disconnect the inner tie rod

ends.

KC184A

NOTE: If tie rods are to be completely removed,

remove the outer tie rod ends from the knuckles at

this time.

5. Remove the cap screw securing the lower steering

post to the bearing. Account for a flat washer.

KC184B

6. Remove the steering post from the ATV.

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Wash the tie rod ends in parts-cleaning solvent. Dry

with compressed air. Inspect the pivot area for wear.

Apply a low-temperature grease to the ends.

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2. Inspect the tie rods for damaged threads or wear.

3. Inspect the tie rods for cracks or unusual bends.

4. Inspect all welded areas for cracks or deterioration.

5. Inspect the steering post and steering-post brackets

for cracks, bends, or wear.

6. Inspect the bearing halves, bearing caps, and bearing

housings for cracks or wear.

7. Inspect the handlebar tube for cracks, wear, or

unusual bends.

8. Inspect the handlebar grips for damage or wear.

INSTALLING

1. Install the steering post into the frame and secure the

lower end in the bearing with a flat washer and cap

screw. Tighten to 40 ft-lb.

KC184B

2. Apply grease to the inner and outer housings of the

upper steering post support; then with the housing

cap in place, secure with the cap screws. Tighten to

20 ft-lb.

KC307A

3. Using red Loctite #271 on the threads, install the tie

rod ends into the lower steering post arm and tighten

to 30 ft-lb; then install new cotter pins.

KC184A

4. Place the handlebar and caps in place on the steering

post and with the handlebar correctly positioned,

tighten the cap screws to 20 ft-lb.

KC0058

5. Install the steering post cover; then install the front

body panel/fender (see Front Body Panel/Fender in

this section).

LCD Gauge

REPLACING

1. Remove the electric panel and disconnect the LCD

gauge connector; then remove three mounting

screws (two in front and one in back of gauge) and

remove the gauge.

KC210G

! WARNING

Always wear safety glasses when using compressed

air.

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KC323A

2. Install the new gauge and secure with the mounting

screws; then connect the gauge to the main harness

and install the electric panel.

Handlebar Grip

REMOVING

1. Loosen but do not remove the cap screw in the end of

the handlebar; then tap lightly on the head to dis-

lodge the handlebar plug.

KC310

KC309A

2. Grasp the end and remove the cap screw, plug, and

end cap.

KC308

3. Using a sharp utility knife, split the handlebar grip

from end to end and peel off the rubber.

4. Using an adhesive solvent, clean all glue residue

from the handlebar.

INSTALLING

1. Apply a liberal amount of Handlebar Grip Adhesive

to the inside of the new grip.

2. Slide the grip onto the handlebar until it is fully

seated with the smooth part of the grip facing up.

NOTE: A quick, firm push is required to seat the

grip completely on the handlebar. Install while the

glue is wet.

3. Wipe off any excess glue; then secure the grip with

the plug, end cap, and cap screw.

Throttle Control

REMOVING

1. Remove the two machine screws securing the throt-

tle control to the handlebar.

2. Slide the grommet out of the lower half of the throt-

tle control; then remove the cable from the actuator

arm.

AF676D

3. Remove the cap screw, lock washer, and washer

securing the actuator arm to the throttle control lever.

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AF677D

4. Remove the actuator arm and account for a bushing.

Note the position of the return spring for installing

purposes.

AF678D

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.

AF679D

2. Using a pair of needle-nose pliers, place the spring

into position on the actuator arm.

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 Periodic Maintenance.

Steering Knuckles

REMOVING AND DISASSEMBLING

1. Secure the ATV on a support stand to elevate the

wheel; then remove the wheel.

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.

5. Remove the hub assembly.

6. Remove the cotter pin from the tie rod end and

remove the tie rod end from the knuckle.

7. Remove the two cap screws securing the ball joints

in the knuckle.

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.

PR287A

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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115

PR288

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Clean all knuckle components.

2. Inspect the bearing for pits, gouges, rusting, or pre-

mature wear.

3. Inspect the knuckle for cracks, breaks, or porosity.

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.

PR287A

2. Install the knuckle to the upper and lower ball joints

and secure with the two cap screws. Tighten to 35 ft-lb.

KC313A

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.

4. Apply a small amount of grease to the hub splines.

5. Install the hub assembly onto the splines of the shaft.

6. Secure the hub assembly with the nut. Tighten only

until snug.

KC305

7. Secure the brake caliper to the knuckle with the

“patch-lock” cap screws. Tighten to 20 ft-lb.

KC283

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.

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.

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11. Install the wheel; then using a crisscross pattern,

tighten to 40 ft-lb.

12. Remove the ATV from the support stand.

Measuring/Adjusting

Toe-Out

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.



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 side.

5. Adjust the handlebar direction until the two measure-

ments are equal; then secure the handlebar.

NOTE: Care must be taken not to allow the handle-

bar to turn while securing it.

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.

6. Using a permanent marker of some type, mark the cen-

ter of each front tire (at a height parallel to the belly

panel).

AF789D

7. Measure the distance between the marks (at a height

parallel to the belly panel) at the front side; then

record the measurement.

8. Push the ATV forward until the marks are parallel to

the belly panel on the back side; then measure the

distance between the marks.

9. The difference in the measurements must show

1/8-1/4 in. toe-out (the front measurement 1/8-1/4 in.

more than the rear measurement).

10. If the difference in the measurements is not within

specifications, adjust both tie rods equally until

within specifications.

NOTE: Prior to locking the jam nuts, make sure the

ball joints are at the center of their normal range of

motion and at the correct angle.

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.

2. Inspect all welds for cracking or bending.

3. Inspect threaded areas of all mounting bosses for

stripping.

4. Inspect for missing decals and/or reflectors.

INSTALLING

1. Place the rack into position on the frame and front

fender panel. Install the cap screws and lock nuts and

finger-tighten only.

2. Install the two cap screws and lock nuts securing the

rack to the fenders. Tighten all hardware securely.

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Front Bumper Assembly

REMOVING

1. Remove the two front cap screws securing the front

rack to the bumper support tubes; then remove two

cap screws and nuts securing the bumper support

tubes to the frame.

2. Remove the through-bolt and lock nut securing the

bumper to the frame; then remove the bumper.

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Clean all bumper components with parts-cleaning

solvent.

2. Inspect all welds for cracking or bending.

INSTALLING

1. Place the front bumper assembly into position and

install the through-bolt. Start the lock nut and fin-

ger-tighten only.

2. Install the existing fasteners in the upper support

tubes to frame and the front rack cap screws. Tighten

the lock nut (from step 1) to 20 ft-lb; then tighten the

cap screws securely.

Front Body Panel/Fender

REMOVING

1. Remove the seat and both side panels.

2. Remove the front rack; then disconnect the head-

light/running light connectors located on the frame.

KC224

NOTE: Use a small screwdriver to disengage the tab

connector allowing the connector assembly to be

removed from the frame.

KC223

3. Remove the cap screws (A); then remove the rein-

stallable rivets (B) and remove the tank cover.

KC219A

KC220

4. Remove the shift knob; then remove the shift mecha-

nism splash shield.

KC211

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5. Remove the screws securing the front body to the

front body supports; then remove the left-side and

right-side footwell fasteners.

KC204A

6. Remove the electric panel; then disconnect the LCD

gauge connector, ignition switch, and accessory out-

let.

KC210G

7. Remove the front body panel/fender panel.

CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Clean all fender components with warm soap and

water.

2. Inspect fenders for cracks and/or loose rivets.

3. Inspect for any missing decals.

INSTALLING

1. Making sure the shift spring is in place and the shift

lever is properly positioned, place the front body

panel/fender panel onto the ATV. With the front rack

in place, loosely install the front rack hardware.

2. Connect the electrical connectors under the electric

panel; then connect the light connectors and attach

onto the frame.

KC210G

KC224

3. Install the screws securing the front body to the front

body supports; then install the left-side and right-side

footwell fasteners. Do not tighten at this time.

4. Place the gas tank cover into position and secure

with the existing hardware; then install the two cap

screws securing the rear of the panel to the frame.

Tighten all cap screws and fasteners securely.

5. Install the electric panel, side panels, and seat.

Exhaust System

REMOVING MUFFLER

1. Remove the two exhaust springs at the muf-

fler/exhaust pipe juncture.

KC170

2. Slide the muffler rearward to clear the mounting lugs

and remove the muffler. Account for a grafoil seal.

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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 muf-

fler/spark arrester, see Periodic Maintenance.

INSTALLING MUFFLER

1. Using a new grafoil seal, place the muffler into posi-

tion engaging the mounting lugs into the grommets;

then slide the muffler forward.

2. Install the two exhaust springs.

Rear Body Panel/Rack

REMOVING

1. Remove the rear rack; then remove two cap screws

securing the rear body panel/fender to the side frame

and the cap screws securing the rear fenders to the

footwells.

KC317A

KC316

2. Disconnect the battery (negative cable first) and

remove from the battery compartment; then discon-

nect the starter relay wires and route the wiring out

of the compartment.

KC322A

3. Remove the auxiliary brake reservoir from the body

but do not disconnect the hose; then route and secure

the hose and reservoir out of the way making sure

not to spill brake fluid.

KC306

4. Using a small screwdriver, remove the light connec-

tors from the frame; then disconnect both connectors

and remove the rear body panel/fender.

KC281

KC279

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CLEANING AND INSPECTING



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

1. Clean all rear body panel components with warm

soap and water.

2. Inspect side panels and rear body panel for cracks

and loose rivets.

3. Inspect threaded areas of all mounting bosses for

stripping.

4. Inspect for missing decals.

INSTALLING

1. Place the rear body panel/fender in place on the

ATV; then secure with the cap screws on the side

frame and the rear rack assembly. Tighten all fasten-

ers securely.

KC317A

KC320A

2. Connect the light connectors and secure to the frame;

then install the battery, starter relay, and auxiliary

brake. Connect all wiring making sure to connect the

positive cables first.

KC279

KC322

3. Secure the rear fenders to the footwells and tighten

the nuts securely.

4. Install the side panels and seat.

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 the seat. The seat should automatically

lock into position.

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Troubleshooting

Problem: Handling too heavy or stiff

Condition Remedy

1. Front wheel alignment incorrect

2. Lubrication inadequate

3. Tire inflation pressure low

4. Tie rod ends seizing

5. Linkage connections seizing

1. Adjust alignment

2. Lubricate steering shaft

3. Adjust pressure

4. Replace tie rod ends

5. Repair - replace connections

Problem: Steering oscillation

Condition Remedy

1. Tires inflated unequally

2. Wheel(s) bent

3. Wheel lug nut(s)/wheel stud(s) loose - missing

4. Wheel hub bearing worn - damaged

5. Tie rod ends worn - loose

6. Tires defective - incorrect

7. A-arm bushings damaged

8. Bolts - nuts (frame) loose

1. Adjust pressure

2. Replace wheel(s)

3. Tighten - replace lug nuts/wheel studs

4. Replace bearing

5. Replace - tighten tie rod ends

6. Replace tires

7. Replace bushings

8. Tighten bolts - nuts

Problem: Steering pulling to one side

Condition Remedy

1. Tires inflated unequally

2. Front wheel alignment incorrect

3. Wheel hub bearings worn - broken

4. Frame distorted

5. Shock absorber defective

1. Adjust pressure

2. Adjust alignment

3. Replace bearings

4. Repair - replace frame

5. Replace shock absorber

Problem: Tire wear rapid or uneven

Condition Remedy

1. Wheel hub bearings worn - loose

2. Front wheel alignment incorrect

3. Tire inflation pressure incorrect

1. Replace bearings

2. Adjust alignment

3. Adjust pressure

Problem: Steering noise

Condition Remedy

1. Cap screws - nuts loose

2. Wheel hub bearings broken - damaged

3. Lubrication inadequate

1. Tighten cap screws - nuts

2. Replace bearings

3. Lubricate appropriate components

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Arctic_cat_2012_425_service_manual Arctic Cat 2012 425 Service Manual

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