2014 Prowler HDX Service

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PROWLER HDX

2014

SERVICE MANUAL

[ROV]

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2014 Arctic
Cat Prowler HDX. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific vehicle 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.
This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures
found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special
tools to be completed. The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools.
All Arctic Cat 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 serious personal injury or even death. A CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the
possibility of damaging part or parts of the vehicle. The symbol  NOTE: identifies supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.

November 2013

Table of Contents
General Information ........................................................ 2
General Specifications.........................................................2
Torque Specifications ..........................................................3
Torque Conversions (ft-lb/N-m)............................................5
Gasoline - Oil - Lubricant.....................................................5
Genuine Parts......................................................................6
Preparation For Storage ......................................................6
Preparation After Storage ....................................................6

Periodic Maintenance...................................................... 7
Periodic Maintenance Chart ................................................7
Lubrication Points ................................................................8
Air Filter ...............................................................................8
Valve/Tappet Clearance.......................................................8
Testing Engine Compression...............................................9
Spark Plug ...........................................................................9
Muffler/Spark Arrester .......................................................10
Engine/Transmission Oil - Filter .........................................10
Front Differential - Rear Drive Lubricant ............................11
Driveshaft/Coupling ...........................................................12
Nuts/Bolts/Cap Screws ......................................................12
Headlight/Taillight-Brakelight .............................................12
Shift Lever..........................................................................13
Hydraulic Brake System ....................................................13
Burnishing Brake Pads ......................................................15
Checking/Replacing V-Belt ................................................15

Steering/Frame/Controls............................................... 17
Electronic Power Steering (EPS).......................................17
Tie Rods ............................................................................19
Steering Assembly.............................................................20
Steering Wheel ..................................................................21
Upper Steering Shaft .........................................................21
Intermediate Steering Shaft Assembly ..............................22
Steering Knuckles..............................................................23
Accelerator Pedal ..............................................................25
Shift Lever..........................................................................25
Shift Cable .........................................................................26
LCD Gauge/Indicator Lights ..............................................27
Checking/Adjusting Front Wheel Alignment ......................28
Front Bumper Assembly ....................................................28
Hood ..................................................................................29
Fenders .............................................................................29
Floor ..................................................................................30
Dashboard .........................................................................30
Belly Panel.........................................................................31
Exhaust System.................................................................31
Cargo Box..........................................................................31
Taillight Assembly ..............................................................32
Seat ...................................................................................32
Troubleshooting .................................................................33

Engine/Transmission .................................................... 34
Troubleshooting .................................................................35
Removing Engine/Transmission ........................................37
Servicing Engine (500) ......................................................40
Servicing Engine (700) ......................................................79
Installing Engine/Transmission ........................................118

Fuel/Lubrication/Cooling ............................................ 121
Electronic Fuel Injection ..................................................121

Gas Tank ......................................................................... 122
Gas/Vent Hoses .............................................................. 124
Oil Filter/Oil Pump ........................................................... 124
Liquid Cooling System .................................................... 125
Radiator........................................................................... 125
Thermostat ...................................................................... 126
Fan .................................................................................. 127
Water Pump .................................................................... 127
Electric Fuel Pump/Fuel Level Sensor ............................ 128
Troubleshooting ............................................................... 130

Electrical System .........................................................131
Battery............................................................................. 131
RPM Limiter .................................................................... 132
Switches.......................................................................... 132
Accessory Receptacle/Connector ................................... 132
Brakelight Switch............................................................. 133
Engine Coolant Temperature (ECT) Sensor ................... 133
Fan Motor ........................................................................ 134
Power Distribution Module (PDM) ................................... 134
Ignition Coil ..................................................................... 134
EFI Sensors/Components ............................................... 135
Speed Sensor ................................................................. 136
Electronic Power Steering (EPS) .................................... 137
Ignition Switch ................................................................. 139
Headlight Switch ............................................................. 139
Drive Select Switch ......................................................... 139
Reverse Override Switch................................................. 140
Front Drive Actuator ........................................................ 140
Stator Coil/Crankshaft Position (CKP) Sensor ................ 141
Starter Motor ................................................................... 142
Starter Relay ................................................................... 142
Electronic Control Module (ECM).................................... 143
Regulator/Rectifier .......................................................... 143
Headlights ....................................................................... 143
Taillight-Brakelight ........................................................... 144
Ignition Timing................................................................. 144
EFI Diagnostic System.................................................... 144
Tilt Sensor ....................................................................... 149
Throttle Position Sensor (TPS)........................................ 150
Troubleshooting ............................................................... 151

Drive System ................................................................152
Front Drive Actuator ........................................................ 152
Front Differential .............................................................. 153
Drive Axles ...................................................................... 164
Rear Gear Case .............................................................. 166
Hub.................................................................................. 169
Hydraulic Brake Caliper................................................... 170
Universal Joints ............................................................... 174
Troubleshooting Drive System......................................... 176
Troubleshooting Brake System........................................ 176

Suspension...................................................................177
Front Shock Absorbers.................................................... 177
Rear Shock Absorbers .................................................... 177
Front A-Arms ................................................................... 183
Rear A-Arms ................................................................... 185
Wheels and Tires ............................................................ 187
Troubleshooting ............................................................... 188

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
MISCELLANY
(front) 26 x 10R-14
(rear) 26 x 12R-14
Tire Inflation Pressure
1.12 kg/cm² (16 psi) - 500
1.41 kg/cm² (20 psi) - 700
Spark Plug Type
NGK CR7E - 500
NGK CPR8E - 700
Spark Plug Gap
0.7-0.8 mm (0.028-0.031 in.)
-500
0.5-0.6 mm (0.019-0.024 in.)
- 700
Gas Tank Capacity
31 L (8.2 U.S. gal.)
Coolant Capacity
2.9 L (3.0 U.S. qt)
Front Differential Capacity
275 ml (9.3 fl oz)*
Rear Drive Capacity
250 ml (8.5 fl oz)*
Engine Oil Capacity (approx)
(500) 3.3 L (3.5 U.S. qt) - Overhaul
2.8 L (3.0 U.S. qt) - Change
(700) 2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Gasoline (recommended)
87 Octane Regular
Unleaded
Engine Oil (recommended)
Arctic Cat ACX All Weather
Synthetic
Front Differential/Rear Drive Lubricant
SAE Approved 80W-90 Hyp(One inch below plug threads)
oid
Belt Width (minimum)
28.5 mm (1.12 in.) - 500
35.0 mm (1.38 in.) - 700
Brake Fluid
DOT 4
Taillight/Brakelight
12V/8W/27W
Headlight
12V/27W (4)

Tire Size

ELECTRICAL SYSTEM
Ignition Timing
Spark Plug Cap
Ignition Coil Resistance

10° BTDC @ 1500 RPM
5000 ohms
(primary) Less than 5.0 ohms - 500
Less than 1 ohm - 700
(secondary) 12k-19k ohms - 500
1.8M ohms - 700
Ignition Coil Primary Voltage
Battery Voltage
Stator Coil Resistance
(CKP Sensor) 150-250 ohms
(AC generator) Less than 1 ohm
AC Generator Output (no load)
60 AC volts @ 5000 RPM
Crankshaft Position Sensor AC Voltage 2.5 volts or more - 500
2.0 volts or more - 700

Specifications subject to change without notice.

CYLINDER, PISTON, AND RINGS (500)
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) 11.6 mm
(2nd) 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/ 0.06 mm
2nd)
Piston Ring Groove Width
(1st) 1.01-1.03 mm
(2nd) 1.21-1.23 mm
(oil) 2.01-2.03 mm
Piston Ring Thickness
(1st) 0.97-.99 mm
(2nd) 1.17-1.19 mm
Piston Pin Bore
(max) 20.008 mm
Piston Pin
(min) 19.994 mm
CYLINDER, PISTON, AND RINGS (700)
Piston Skirt/Cylinder Clearance (min)
0.06 mm
Cylinder Bore
101.992-102.008 mm
Piston Diameter 15 mm from Skirt End
101.930-101.949 mm
Piston Ring Free End Gap
(1st/2nd)
12.5 mm
Bore x Stroke
102 x 85 mm
Cylinder Trueness (max)
0.01 mm
Piston Ring End Gap - Installed (min)
0.38 mm
Piston Ring to Groove Clearance (max)
0.03 mm
(1st/2nd)
Piston Ring Groove Width
(1st/2nd)
1.202-1.204 mm
(oil)
2.01-2.03 mm
Piston Ring Thickness
(1st/2nd)
1.970-1.990 mm
Piston Pin Bore (max)
23.0 mm
Piston Pin Outside Diameter (min)
22.99 mm

VALVES AND GUIDES (500)
Valve Face Diameter

(intake) 35.0 mm
(exhaust) 30.5 mm
Valve/Tappet Clearance
(intake) 0.10 mm
(cold engine)
(exhaust) 0.17 mm
Valve Guide/Stem
(intake) 0.10 mm
Clearance (max)
(exhaust) 0.30 mm
Valve Guide/Valve Stem Deflection
0.35 mm
(Wobble Method) (Max)
Valve Face Radial Runout
(max) 0.15 mm
Valve Guide Inside Diameter
5.000-5.012 mm
Valve Stem Outside Diameter
(intake) 4.975-4.990 mm
(exhaust) 4.955-4.970 mm
Valve Stem Runout
(max) 0.10 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)
VALVES AND GUIDES (700)
Valve Face Diameter
(intake)
31.6 mm
(exhaust)
27.9 mm
Valve/Tappet Clearance
(intake)
0.1016 mm
(cold engine)
(exhaust)
0.1524 mm
Valve Guide/Stem Clearance
0.013 mm
Valve Guide/Valve Stem Deflection
0.35 mm
(Wobble Method) (Max)
Valve Guide Inside Diameter
5.000-5.012 mm
Valve Stem Outside Diameter
4.972-4.987 mm
Valve Stem Runout
(max)
0.1 mm
Valve Head Thickness
(min)
2.3 mm
Valve Face/Seat Width (min)
(intake)
2.25 mm
(exhaust)
2.60 mm
Valve Seat Angle
45° +15’/+30’
Valve Face Radial Runout
(max)
0.2 mm
Valve Spring Free Length
(min)
38.7 mm
Valve Spring Tension @ 31.5 mm
19.0 kg (42 lb)

CRANKSHAFT (500)
Connecting Rod (small end)
(max)
20.021 mm
Connecting Rod (big end side-to-side)
0.7 mm
(max)
Connecting Rod (big end width)
21.95-22.00 mm
Connecting Rod (small end deflection)
3.0 mm

DRIVE TRAIN COMPONENTS
Part

(max)
Crankshaft (web-to-web)
Crankshaft Runout

60.9 mm
0.03 mm
CRANKSHAFT 700)
Connecting Rod (small end inside (max)
23.021 mm
(diameter)
Connecting Rod (big end side-to-side)(min) 0.6 mm
Connecting Rod @ 150 mm
(max)
0.3 mm
(small end deflection)
Crankshaft (web-to-web)
(min)
71 mm
Crankshaft Runout
(max)
0.03 mm
CAMSHAFT AND CYLINDER HEAD (500)
Cam Lobe Height (min)
(intake)
34.71 mm
(exhaust)
34.48 mm
Camshaft Journal Holder(right & center)
22.01-22.04 mm
Inside Diameter
(left)
17.51-17.54 mm
Camshaft Journal Outside(right & center) 17.466-17.480 mm
Diameter
(left)
21.966- 21.980 mm
Camshaft Runout
(max)
0.03 mm
Rocker Arm Inside Diameter
10.00-10.15 mm
Rocker Arm Shaft Outside Diameter
9.972-9.987 mm
Cylinder Head/Cover Distortion (max)
0.05 mm
Camshaft Journal/Cylinder Head
0.074 mm
Clearance
(max)
CAMSHAFT AND CYLINDER HEAD (700)
Cam Lobe Height
(min)
33.53 mm
Camshaft Journal Oil Clearance (max)
0.04 mm
Camshaft Runout
(max)
0.05 mm
Rocker Arm Inside Diameter
(max)
12.018 mm
Rocker Arm Shaft Outside Diameter(min) 11.97 mm
Cylinder Head/Cover Distortion (max)
0.05 mm

(max)

Torque Specifications
NOTE: Torque specifications have the following tolerances:
Torque (ft-lb)
0-15
16-39
40+

Tolerance
±20%
±15%
±10%

Exhaust Pipe
Spark Arrester
O2 Sensor

Part Bolted To
Cylinder Head
Muffler

Exhaust Pipe
BRAKE COMPONENTS
Brake Disc****
Hub
Brake Hose
Caliper
Brake Hose
Master Cylinder
Master Cylinder
Frame
Caliper****
Knuckle
Rear Driveline ****
Rear Differential
ELECTRICAL COMPONENTS
Coil*
Frame

Rear Differential/Gear Case Frame
Drive Coupler (Front)
Front Drive Flange
Front Engine Mounting
Frame
Bracket
Rear Engine Mounting Bracket Frame
Engine Mounting Through-Bolt Frame
Front Differential
Frame/Differential Bracket
Rear Output Flange
Rear Driven Flange
Input Shaft Assembly
Gear Case Housing
Pinion Housing
Differential Housing
Secondary Shaft Bearing
Crankcase
Housing
Rear Cradle
Frame
Driveshaft (Front/Rear)
Engine
Shift Cable Bracket
Engine
Front Input Drive Flange
Front Drive Yoke Flange
Driveline
Rear Drive Input Flange
Differential Housing Cover*** Differential Housing
Thrust Button**
Gear Case Cover
Drive Bevel Gear Nut***
Shaft
Lock Collar
Differential Housing
Hub Nut
Front/Rear Shaft/Axle (min)
Oil Drain Plug
Front Differential - Rear
Drive
Oil Fill Plug
Front Differential - Rear
Drive
Oil Drain Plug
Engine
Wheel
Hub
STEERING COMPONENTS
Steering Wheel**
Steering Wheel Shaft
Steering Wheel Shaft***
Intermediate Shaft (Upper)
Intermediate Shaft (Lower)*** Steering Pinion Shaft
Rack and Pinion Assembly
Frame
Tie Rod
Rack
Tie Rod End**
Knuckle
Jam Nut
Tie Rod End
Steering Shaft Coupler
EPS Input Shaft
EPS Cradle Bracket
Frame
EPS Assembly
Frame
EPS Assembly
Rack Coupler
Intermediate Shaft Coupler
Intermediate Shaft
Steering Shaft Housing (6
Frame
mm)
Steering Shaft Housing (8
Frame
mm)

CHASSIS/ROPS ASSEMBLY
Shift Axle Support
Frame

EXHAUST COMPONENTS
Part

Part Bolted To

Torque
ft-lb N-m
20 27
50
5
in.-lb
19 26
15
20
20
25
20
12

20
27
27
34
27
16

Torque
ft-lb N-m
38 48
40 54
45 61
45
40
38
40
23
23
28

61
54
52
54
31
31
38

25
20
8
20
20
23
8
87
125
200
45
in.-lb
16

34
27
11
27
27
31
11
118
170
272
5

16
80

22
108

25
31
36
35
37
30
10
11
20
35
11
31
8

34
42
49
48
50
41
14
15
27
48
15
42
11

48
in.-lb
Front/Rear ROPS Tube
Arm Rest/Steering Support 35
Top ROPS Support
Front/Rear ROPS Tubes
35
Rear ROPS Tube
Lower ROPS Support
35
Shift Cable
Shift Arm Stud
8
Shift Cable Mounting/Adjuster Shift Cable
20
Cargo Box Hinge
Cargo Box Frame
20
Side Panel/Spacer
Cargo Box Frame
25
Tilt Pivot Bushing
Cargo Box Frame
15
Latch Striker
Cargo Box Liner
60
in.-lb

5
48
48
48
34
27
27
34
20
7

* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #270 **** w/“Patch-Lock”

SUSPENSION COMPONENTS (Front)

Part

Part Bolted To

A-Arm
Knuckle
Shock Absorber
Shock Absorber
Knuckle

Frame
Ball Joint
Frame/Upper A-Arm
Lower A-Arm
A-Arm
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket
Frame
A-Arm
Frame
Shock Absorber
Lower A-Arm
Shock Absorber
Frame
Knuckle
A-Arm

Torque
ft-lb N-m
35
35
35
20
35

48
48
48
27
48

35
35
35
35
35

48
48
48
48
48

147
8
8
10
21
8
28
20
8
63
147
8
107
11
7
8
8
26
8
147
59
11
8
10
8
20
8
28

199
11
11
13.5
28
11
38
27
11
86
199
11
146
15
9.5
11
11
35
11
199
80
15
11
13.5
11
27
11
38

ENGINE/TRANSMISSION (500)
Clutch Shoe**

Crankshaft

Clutch Cover/Housing Assembly

Crankcase

Left-Side Cover

Crankcase

Crankcase Half (6 mm)

Crankcase Half

Crankcase Half (8 mm)

Crankcase Half

Cylinder Nut

Crankcase Half

Cylinder Head (Cap Screw)

Crankcase

Cylinder Head Nut

Cylinder

Cylinder Head Cover

Cylinder Head

Oil Pump Drive Gear**

Crankshaft

Driven Pulley Nut**

Driveshaft

Ground Cable

Engine

Magneto Rotor Nut

Crankshaft

Cam Sprocket**

Camshaft

Valve Adjuster Jam Nut

Valve Adjuster

Starter Motor

Crankcase

Oil Fitting

Engine

Starter One-Way Clutch

Flywheel

Oil Pump*

Crankcase

Movable Drive Face Nut**

Clutch Shaft

Output Shaft Flange Nut

Output Shaft

Cam Chain Tensioner Guide

Cylinder

Valve Inspection Cover

Cylinder Head Cover

Cam Chain Tensioner

Cylinder

Magneto Cover

Crankcase

Rear Driveline

Output Drive Flange

Water Pump Cover/Housing

Magneto Cover

Water Pump Drive Gear

Crankshaft

ENGINE/TRANSMISSION (700)
Clutch Shoe**
Crankshaft
Clutch Cover/Housing Assem- Crankcase
bly
Crankcase Half (6 mm)
Crankcase Half
Crankcase Half (8 mm)
Crankcase Half
Cylinder Head (Cap Screw)
Crankcase
Cylinder Head Nut (6 mm)
Cylinder
Cylinder Head Nut (8 mm)
Cylinder
Valve Cover
Cylinder Head
Driven Pulley Nut
Driveshaft
Movable Drive Face Nut**
Driveshaft
Ground Wire
Engine
Magneto Cover
Crankcase
Tappet Cover
Valve Cover
Crankshaft Spacer
Crankshaft
Oil Pump Cover**
Crankcase
Oil Pump Drive Gear**
Crank Balancer Shaft
Output Shaft Flange Nut**
Output Shaft
One-Way Clutch**
Rotor/Flywheel
Outer Magneto Cover
Side Cover
Magneto Rotor Nut**
Crankshaft
Cam Sprocket**
Camshaft
Speed Sensor Housing
Crankcase
V-Belt Cover
Crankcase
Output Yoke Nut**
Secondary Driven Output
Shaft
Output Shaft Flange Yoke/
Output Shaft
Nut**
Secondary Shaft Bearing
Crankcase Half
Housing
Stator Coil*
Magneto Cover
Intake Manifold Boot Clamp Intake Boot
Ground Wire

Engine

221 300
8
11
10
20
40
8
18
8.5
80
165
8
8
9
28
8
62
62
26
8
105
11
8
8
74

14
27
54
11
24
11.5
109
224
11
11
12
38
11
84
84
35
11
143
15
11
11
100

13 18
30 in.- 3.4
lb
8
11

RECOMMENDED ENGINE/
TRANSMISSION OIL

Torque Conversions
(ft-lb/N-m)

CAUTION

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

1.4

35.4

69.4

103.4

2.7

36.7

70.7

104.7

4.1

38.1

72.1

106.1

5.4

39.4

73.4

107.4

6.8

40.8

74.8

108.8

8.2

42.2

76.2

110.2

9.5

43.5

77.5

111.5

10.9

44.9

78.9

112.9

12.2

46.2

80.2

114.2

13.6

47.6

81.6

115.6

117

16.3

50.3

84.3

118.3

17.7

51.7

85.7

119.7

121

20.4

54.4

88.4

122.4

21.8

55.8

89.8

123.8

23.1

57.1

91.1

125.1

24.5

58.5

92.5

126.5

25.8

59.8

93.8

127.8

27.2

61.2

95.2

129.2

28.6

62.6

96.6

130.6

29.9

63.9

97.9

131.9

31.3

65.3

99.3

133.3

32.6

66.6

100.6

134.6

102

100

136

Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methane are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.

CAUTION
Do not use white gas. Only Arctic Cat approved gasoline additives should be used.

Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.

The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifically formulated for use in this Arctic Cat engine.
Although Arctic Cat ACX All Weather synthetic engine
oil is the only oil recommended for use in this engine,
use of any API certified SM 0W-40 oil is acceptable.

OILCHARTJ

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 vehicle front differential
and rear drive.

CAUTION
Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive
damage.

FILLING GAS TANK

! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the gas tank near any open flames or with
the engine running. DO NOT SMOKE while filling the
gas tank.

Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expansion room must be maintained in the tank particularly if
the tank is filled with cold gasoline and then moved to a
warm area

! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.

Tighten the gas tank cap securely after filling the tank.

! WARNING
Do not over-fill the gas tank.

Genuine Parts
When replacement of parts is necessary, use only genuine
Arctic Cat parts. They are precision-made to ensure high
quality and correct fit. Refer to the appropriate Illustrated
Parts Manual for the correct part number, quantity, and
description.

Preparation For Storage
CAUTION
Prior to storing the vehicle, it must be properly serviced
to prevent rusting and component deterioration.

1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
2. Clean the vehicle thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire vehicle. Allow it 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. Using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for
a period of 10 to 20 seconds; then stop the engine.
Install the air filter and housing cover.

CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.

4. Plug the exhaust hole in the exhaust system with a
clean cloth.
5. Apply light oil to the 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 coolant.
8. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a
clean, dry area.
9. Store the vehicle indoors in a level position.

CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the vehicle
causing rusting.

Preparation After
Storage
Taking the vehicle out of storage and correctly preparing
it will assure many miles and hours of trouble-free riding.
1. Clean the vehicle thoroughly.
2. Clean the engine. Remove the cloth from the exhaust
system.
3. Check all control wires and cables for signs of wear
or fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the battery
cables.

CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the ignition system.

CAUTION
Connect the positive battery cable first; then the negative.

7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
9. Check tire pressure. Inflate to recommended pressure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as necessary.

SPECIAL TOOLS

Periodic Maintenance
This section has been organized into sub-sections which show
common maintenance procedures for the Arctic Cat ROV.

A number of special tools must be available to the technician when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appropriate tool description.
Description
Compression Tester Kit
Oil Filter Wrench

p/n
0444-213
0644-389

Timing Light
Valve Clearance Adjuster

0644-296
0444-255

NOTE: Special tools are available from the Arctic
Cat Service Department.

Periodic Maintenance
Chart
A = Adjust

I = Inspect

C = Clean

Item
Battery
Fuses
Air Filter
Valve/Tappet Clearance
Engine Compression
Spark Plug
Muffler/Spark Arrester
Gas Hoses
Throttle Cable Ends/Accelerator Pedal
Pivot
Engine-Transmission Oil Level
Engine-Transmission Oil/Filter
Front Differential - Rear Drive Lubricant
Tires/Air Pressure
Steering Components
V-Belt
Suspension (Ball joint boots, drive axle
boots front and rear, tie rods, differential
and rear drive bellows)
Nuts/Bolts/Cap Screws
Ignition Timing
Headlight/Taillight-Brakelight
Switches
Shift Lever
Gauges/Indicators
Frame/Welds
Electrical Connections
Complete Brake System
(Hydraulic)
Brake Pads
Brake Fluid
Brake Hoses
Coolant/Cooling System
Wheel Lug Nuts

R = Replace

Initial Service
After Break-In
(First Month or
100 Miles)
I

T = Tighten

Every Every Month or
Day Every 100 Miles

L = Lubricate
Every 3
Months or
Every 300
Miles

Every 6
Months or
Every 500
Miles

Every Year or
Every 1500
Miles

As
Needed

C
R
R
A

I
I*

I
I

R (4000 Mi or
18 Mo)
R
R (2 Yrs)
A-R

C
I
I

I
I

C-L

I
R
I
I
I
I
I

A
R
R (4 Yrs)
R
R
R
R

R*/R**/R***
I
I
I

I
l

A
I

I
I

I
I
I
I
T

R
R
A-L
R

l
l

I*
I
I
I

R
R (2 Yrs)
R (4 Yrs)
R (2 Yrs)

* Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every
1,000 miles or every year.

6. Clean any dirt or debris from inside the filter housing. Be sure no dirt enters the throttle body.

Lubrication Points

7. Install the air filter and cover and lower the cargo box.

It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the
components using the following list as reference.

CHECKING AND CLEANING DRAINS
1. Inspect the “duck-bill” drain beneath the main housing for debris and for proper sealing.
2. Remove the drain tube and clean out any water, oil,
or debris. Reinstall and secure with the clamp.

A. Accelerator Pedal Pivot/Cable Ends
B. Brake Pedal Pivot
C. Shift Cable

Valve/Tappet Clearance
Air Filter

To check and adjust valve/tappet clearance, use the following procedure.

CAUTION

NOTE: The engine must be cold for this procedure.

Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.

NOTE: The seat, seat back, seat base, and spark
plug must be removed for this procedure.

1. Raise the cargo box; then remove any dust and debris
from around the filter housing.

1. Remove the spark plug and timing inspection plug; then
remove the tappet covers (for more detailed information, see the Engine/Transmission section - Servicing
Top-Side Components).

2. Unsnap the four spring-clip fasteners and remove the
cover.

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 clearance is within specifications. Tighten each jam nut
securely after completing the adjustment.

CAUTION
HDX050A

3. Fill a wash pan larger than the element with a nonflammable cleaning solvent; then dip the element in
the solvent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil are
available from Arctic Cat.

The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve component damage.
Intake
Exhaust

VALVE/TAPPET CLEARANCE
0.1016 mm (0.004 in.)
0.1524 mm (0.006 in.)

4. Dry the element.
5. Put the element in a plastic bag; then pour in air filter
oil and work the element. Reattach the filter to the
filter screen.
NOTE: Carefully squeeze excess oil from the element.

CAUTION
A torn air filter can cause damage to the vehicle 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.

CC007D

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.

4. Attach the Compression Tester Kit.
5. While holding the throttle in the full-open position,
crank the engine over with the electric starter until the
gauge stops climbing (five to 10 compression strokes).
PSI Hot (WOT)

PSI Cold (WOT)

125-145

100-140

6. If compression is abnormally low, inspect the
following items.
A. Starter cranks engine over.

D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.

B. Gauge is functioning properly.

NOTE: Refer to the specifications in Feeler
Gauge Procedure sub-section for the proper valve/
tappet clearance.

D. Valve/tappet clearance correct.

NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

F. Intake obstructed.
NOTE: To service top-side components, see the
Engine/Transmission section.

E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.

7. Pour approximately 30 ml (1 fl oz) of oil into the
spark plug hole, reattach the gauge, and retest compression.

3. Install the spark plug; then install the timing inspection plug.

8. If compression is now evident, service the piston
rings (see the appropriate Engine/Transmission - Top
Side Components).

4. Place the two tappet covers with O-rings into position. Tighten the cap screws to 9 ft-lb.

C. Throttle in the full-open position.

E. Engine warmed up.

Spark Plug
Testing Engine
Compression
To test engine compression, use the following procedure.

A light brown insulator indicates that the 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.

NOTE: The engine should be warm (operating
temperature) and the battery fully charged for an
accurate compression test. The throttle must be in
the wide-open throttle (WOT) position. In the event
the engine cannot be run, cold values are
included.
NOTE: The seat, seat back, and seat base must
be removed for this procedure.

1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.

! WARNING
Always wear safety glasses when using compressed
air.

3. Remove the spark plug; then attach the high tension
lead to the plug and ground the plug on the cylinder
head well away from the spark plug hole.

ATV-0051

CAUTION
Before removing the spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.

Adjust the gap to 0.5-0.6 mm (0.019-0.024 in.).

NOTE: If the screen or gasket is damaged in any
way, it must be replaced.

3. Install the spark arrester assembly and gasket and
secure with the cap screws. Tighten the cap screws to
48 in.-lb.

Engine/Transmission Oil Filter
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.

Muffler/Spark Arrester

OIL - FILTER
Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the vehicle on level ground.
2. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan; then remove the
center console, seat, seat back, and seat base.

Clean the spark arrester using the following procedure.

! WARNING
Wait until the muffler cools to avoid burns.

1. Remove the cap screws securing the spark arrester
screen assembly to the muffler; then loosen and
remove the spark arrester. Account for a gasket.

PR078A

3. Using the Oil Filter Wrench and a ratchet handle (or a
socket or box-end wrench), remove the old oil filter.
NOTE: Clean up any excess oil after removing the filter.

4. Apply oil to a new filter O-ring and check to make sure it
is positioned correctly; then install the new oil filter.
Tighten securely.
PR498

5. Install the engine drain plug and tighten to 16 ft-lb. Pour
the specified amount of the recommended oil in the filler
hole.
500

PR499

2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the screen.
10

HDX042A

700

1. Remove the level plug (B); the lubricant should be
level with the bottom threads.

HDX042A

CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.

6. Start the engine (while the vehicle is outside on level
ground) and allow it to idle for a few minutes.
7. Turn the engine off and wait approximately one minute;
then unscrew the oil level stick and wipe it with a clean
cloth.

HDX221A

2. If low, remove the fill plug (A) and add the appropriate
lubricant until it appears at the bottom of the level plug
threads.
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove each fill plug.
3. Drain the lubricant into a drain pan by removing in turn
the drain plug from each.

8. Install the oil level stick and thread into the engine case.
9. Remove the oil level stick; the oil level must be within
the operating range but not exceeding the upper mark.

HDX255

GZ461A

CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.

10. Inspect the area around the drain plug and oil filter for
leaks.

Front Differential - Rear
Drive Lubricant
To check lubricant, use the following procedure.

HDX220A

4. After all the lubricant has been drained, install the drain
plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of recommended lubricant
into the fill hole.
6. Install the fill plug and tighten to 16 ft-lb.
11

NOTE: If the lubricant is contaminated with water,
inspect the drain plug, fill plug, and/or bladder.

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.
C. Universal joints worn or missing bearings.

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.

Headlight/TaillightBrakelight
HEADLIGHT
NOTE: The bulb portion of the headlight is fragile.
HANDLE WITH CARE. When replacing the headlight
bulb, do not touch the glass portion of the bulb. If the
glass is touched, it must be cleaned with a dry cloth
before installing. Skin oil residue on the bulb will
shorten the life of the bulb.

2. Rotate the bulb socket counterclockwise to remove it
from the light assembly; then pull straight out on the bulb.
Push the new bulb straight into the socket.
3. Install the bulb and socket into the light assembly and turn
clockwise to lock in place.
4. Install the taillight-brakelight assembly on the canopy
support.
CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically. The geometric center
of the HIGH beam light zone is to be used for vertical aiming.
1. Position the vehicle on a level floor so the headlights are
approximately 6.1 m (20 ft) from an aiming surface (wall
or similar aiming surface).
NOTE: There should be an average operating load on
the vehicle when adjusting the headlight aim.

2. Measure the distance from the floor to the mid-point of
each headlight.
3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal marks
on the aiming surface directly in front of the headlights.
5. Switch on the lights. Make sure the HIGH beam is on. DO
NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is when the
most intense beam is centered on the vertical mark 5 cm
(2 in.) below the horizontal mark on the aiming surface.

! WARNING
Do not attempt to remove the bulb when it is hot. Severe
burns may result.

To replace the headlight bulb, use the following procedure.
1. Remove the wiring harness connector from the back
of the headlight.
2. Grasp the bulb socket, turn it counterclockwise and
remove, and pull the bulb straight out of the socket.

0740-647

7. Using the adjuster knob, adjust each headlight until correct aim is obtained.

3. Install the new bulb into the socket and rotate it completely clockwise in the housing.
4. Install the wiring harness connector.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the following
procedure.
1. Remove the two machine screws and remove the
light assembly.
CD714A

Shift Lever
CHECKING SHIFT CABLE
ADJUSTMENT
1. Turn the ignition switch on; then with the shift lever
in the neutral position, look for the (N) indication on
the LCD. Shift into high range and look for the (H)
indication, low range for the (L) indication, and
reverse for the (R) indication.
2. Shift the transmission into park and observe that the
(P) illuminates on the LCD gauge.
ADJUSTING SHIFT CABLE
To adjust the shift cable, use the following procedure.
1. Place the transmission in park; then tilt the cargo
box.
2. Make sure the shift lever is in park; then remove the
E-clip securing the cable end to the shift arm stud.

PR568A

4. Install the E-clip; then tighten the nuts (A) and (B) to
8 ft-lb.
5. Check each gear shift position for proper gear selection and make sure the proper icon illuminates on the
LCD.

Hydraulic Brake System
NOTE: This ROV is equipped with hydraulic
brakes at all four wheels.

CHECKING/BLEEDING
The hydraulic brake system has been filled and bled at
the factory. To check and/or bleed a hydraulic brake system, use the following procedure.
1. With the master cylinder in a level position, check
the fluid level in the reservoir. If the level in the reservoir is not above the MIN, add DOT 4 brake fluid.

700
HDX251

500
PR095
HDX254

3. Loosen nuts (A) and (B) and adjust the cable housing
to align the shift cable end to the shift arm stud.

2. Depress the brake pedal several times to check for a firm
brake. If the brake is not firm, the system must be bled.
To bleed the brake system, use the following procedure.
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid; then install and secure the cover.
B. Slowly depress the brake pedal several times.

C. Remove the protective cap, install one end of a
clear hose onto the RIGHT REAR (700) or REAR
DRIVELINE (500) bleeder screw, and direct the
other end into a container; then while holding
slight pressure on the brake pedal, open the
bleeder screw and watch for air bubbles. Close the
bleeder screw before releasing the brake pedal.
Repeat this procedure until no air bubbles are
present. Then the rear left repeat B and C.

D. At this point, perform steps B and C on the REAR
LEFT bleeder screw (700 only); then move to the
FRONT LEFT bleeder screw and follow the same
procedure. Finally complete the procedure on the
FRONT LEFT bleeder screw.
E. Repeat steps B and C until the brake pedal is firm.
3. 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.

CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must be
taken as brake fluid is very corrosive to painted surfaces.

INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
REAR 500
HDX236A

REAR 700

CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thickness of each of the brake pads as follows.
1. Remove the wheel corresponding to the brake being
checked.
2. Measure the thickness of each brake pad.

AF637D

FRONT

PR376A

3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a set.
PR377C

NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always
a sufficient amount of brake fluid. When the level
falls below MIN, refill the reservoir before the
bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will
result in air in the system.

4. To replace the brake pads, use the following procedure.
A. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads from
the caliper.

3. Repeat procedure 20 times until brake pads are burnished.

Checking/Replacing VBelt
REMOVING
1. Remove the seat, seat back, and seat base.
PR237

B. Install the new brake pads.

2. Remove the floor (see Steering/Frame/Controls);
then remove the gas tank (see Fuel/Lubrication/
Cooling).

C. Secure the caliper holder to the knuckle with new
“patch-lock” cap screws. Tighten to 20 ft-lb.

3. Remove the screws securing the right-side storage compartment; then remove the compartment.

4. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover. Remove the cover. Account for two dowel
pins.
5. Remove the nut securing the movable drive face;
then remove the face. Account for the flat washer
and spacer.
NOTE: Keep the drive face plate in contact with
the drive face when removing or installing the
drive face to prevent the rollers from falling out.
PR377B

5. Install the wheel. Tighten in 20 ft-lb increments to 40
ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
6. Burnish the brake pads.
BRAKE DISC
Using a micrometer, measure the thickness of the brake
disc in the contact surface. If thickness is 0.125 in. or
less, the disc must be replaced. To replace the brake disc,
see Drive System – Hub.

Burnishing Brake Pads

CD963

Brake pads must be burnished to achieve full braking
effectiveness. Braking distance will be extended until
brake pads are properly burnished. To properly burnish
the brake pads, use the following procedure.

! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.

1. Choose an area large enough to safely accelerate the
vehicle to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then depress the brake pedal
to decelerate to 0-5 mph.

CD966A

6. Install one of the V-belt cover cap screws into the
driven pulley fixed face; then turn the cap screw
clockwise to spread the pulley faces. Remove the Vbelt.

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

2. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the driveshaft.
Secure the drive face with a washer and nut (coated with
red Loctite #271). Tighten the nut to 165 ft-lb
.

CAUTION
Make sure the movable drive face plate is fully engaged
onto the splines of the clutch shaft before tightening the nut
or false torque readings may occur. This will cause the
assembly to loosen damaging the shaft and clutch face
plate.

PR476A

GZ485A

NOTE: At this point, remove the cap screw from
the driven pulley face.
GZ085

INSTALLING
1. Place the V-belt into position on the driven pulley and
over the front shaft.

3. Rotate the V-belt and driven pulley/clutch until the Vbelt is flush with the top of the driven pulley.
4. Place the V-belt cover gasket into position; then with the
dowel pins in position, install the cover and secure with
the cap screws making sure the different-lengthed cap
screws are in their proper location. Tighten the cap
screws to 8 ft-lb.
5. Install the storage compartment and secure with the
screws.
6. Install the gas tank (see Steering/Frame/Controls); then
install the floor (see Fuel/Lubrication/Cooling).
7. Install the seat, seat back, and seat base.

GZ085

Steering/Frame/Controls
The following steering components should be inspected
periodically to ensure safe and proper operation.
A. Steering wheel secure.
B. Steering has equal and complete full-left and fullright capability.
C. Steering sector mounting bolts tight.
PR760A

D. Ball joints not worn, cracked, or damaged.

4. Remove the steering wheel; then remove the steering
wheel boot support.

E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
H. Steering wheel tilt locks securely.
The frame and welds should be checked periodically for
damage, bends, cracks, deterioration, broken components, and missing components.

Electronic Power
Steering (EPS)
PR762A

REMOVING
NOTE: Certain models are equipped with electronic power steering. Thoroughly troubleshoot
the EPS system prior to replacing the EPS assembly (see the Electrical System section) as there are
several possible external causes for system failure.

5. Remove the sheet metal screws securing the dash
assembly to the frame; then disconnect the gauge
plug and the dash harness. Remove the dash assembly.
6. Remove the four cap screws and nuts securing the
steering shaft housing to the steering support; then
remove the cap screw securing the intermediate shaft
yoke to the steering shaft.

1. Support the vehicle on appropriate stands or a lift;
then remove the left front wheel and left front shock
absorber.
2. Remove the front storage box; then disconnect the
two electrical connectors from the EPS assembly.

PR764A

PR759A

3. Remove the cap screw securing the intermediate
shaft yoke to the EPS assembly input shaft.
17

PR765A

7. Remove the steering shaft housing and shaft from the
steering support and intermediate shaft; then remove
the intermediate shaft from the EPS input shaft.
8. Remove four cap screws securing the EPS assembly
to the frame; then remove the cap screw securing the
rack coupler to the EPS output shaft.

PR776A

NOTE: Alignment need only be approximate as
final alignment is not possible until the EPS is
engaged with the coupler.

3. Install the EPS assembly into the coupler turning the
EPS shaft slightly to align the index spline; then seat
the EPS firmly onto the frame.
4. Install four cap screws securing the EPS assembly to
the frame and tighten to 35 ft-lb.
5. Install the cap screw in the EPS to rack coupler and
tighten to 11 ft-lb.
6. Connect the two electrical connectors; then align the
slot in the intermediate steering shaft coupler to the
index (flattened) spline on the EPS input shaft and
install. Install but do not tighten the cap screw.

PR761A

NOTE: No repairs are authorized on the EPS
assembly and it must be replaced as a complete
assembly.

INSTALLING
1. Align the slot in the rack coupler to the notch in the
frame (front wheels centered).
PR759B

7. Install the steering shaft housing with steering shaft
connecting the steering shaft and intermediate shaft
first; then slide the housing into place on the steering
support.
8. Secure the steering shaft housing to the frame with
four cap screws and nuts. Tighten the 6 mm nuts to 8
ft-lb and the 8 mm nuts to 20 ft-lb.

PR766A

2. Rotate the EPS shaft to align the index (flattened)
spline with the slot in the rack coupler.

PR764B

PR780

9. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb; then tighten the cap screw
(from step 6) to 11 ft-lb.

4. Using an appropriate crow-foot and backing wrench,
remove the tie rod assembly.
NOTE: Tie rods come as a complete assembly.
No further disassembly is required.

5. Remove and discard the lock washer.
INSTALLING
1. Remove the tie rod end and lock nut from the tie rod;
then install the tie rod boot onto the tie rod.
2. Install the tie rod lock nut and tie rod end.
3. Coat the tie rod joint threads with red Loctite #271;
then with a new lock washer, thread the tie rod into
the rack.
PR765A

10. Install the front storage box; then install the dash and
connect the two electrical connectors. Secure with
sheet metal screws and tighten securely. Do not overtighten.
11. Install the steering housing boot; then install the boot
support and secure with two machine screws.
12. Install the steering wheel; then apply a drop of red
Loctite #271 to the threads of the castle nut. Secure
the steering wheel and tighten to 25 ft-lb. Install the
lock clip and cover.

Tie Rods

PR784

4. While holding the rack shaft with a wrench, tighten
the tie rod joint to 37 ft-lb using an appropriate crowfoot.

REMOVING
1. Remove the steering rack assembly (see Steering
Assembly in this section).
2. Support the steering rack assembly in a suitable
holding fixture or bench vise; then cut the securing
band and slide the boot toward the outer tie rod end.
3. Using a punch or chisel, bend the lock washer away
from the flats on the tie rod joint.

PR781

NOTE: Always attach the crow-foot to the torque
wrench with the open end 90° to the torque wrench
handle to ensure accurate torque application.

PR301

3. Remove the EPS cradle bracket; then remove the cap
screws securing the steering rack assembly to the
rack bracket and remove from the left side.
PR528A

5. Install the boot onto the rack and secure with the
nylon tie.
6. Center the rack in the steering rack assembly and
align the white paint line on the pinion with the mark
on the rack housing.

INSPECTING
1. Inspect the tie rod ends for damaged threads, torn
boots, or excessive wear.
2. Inspect the tie rods for bends or deformation.
3. Inspect the rack and pinion-to-tie rod boots for tears
or deterioration.

PR785A
PR785

Steering Assembly
REMOVING
NOTE: If equipped, the EPS assembly must be
removed prior to removing the steering assembly.

1. Remove the right front wheel.
2. Remove the cotter pins and nuts securing the tie rod
ends to the knuckles; then remove the tie rod ends
from the knuckles.

4. Check boot clamps for security.
5. Check that the steering assembly operates smoothly
with no binding from full-left to full-right position.
6. Inspect for grease seepage from the steering assembly.
NOTE: The steering assembly (rack and pinion) is
not repairable and must be replaced as an assembly; however, the tie rods and boots are replaceable.

INSTALLING
1. From the left side, install the steering assembly (rack
and pinion) to the frame assembly and secure with
two cap screws. Tighten to 35 ft-lb.
2. Install the EPS cradle bracket and secure with four
cap screws. Do not tighten the cap screws at this
time.

NOTE: If the hole in the steering shaft does not
align with the slots in the castle nut, tighten the
nut slightly until the next slot aligns with the hole.

PR773A

3. Place the tie rod ends into the knuckles and secure
with the castle nuts (coated with red Loctite #271).
Tighten to 30 ft-lb; then install new cotter pins.
NOTE: If the slots in the castle nut are not
aligned with the hole in the tie rod end, tighten
until the cotter pin can be installed.

4. Install the EPS assembly; then tighten the cap screws
(from step 2) to 20 ft-lb.
5. Install the wheel and tighten to 80 ft-lb.

Steering Wheel
REMOVING

HDX131A

Upper Steering Shaft
REMOVING
1. Remove the dashboard (see Dashboard in this section).
2. Remove the four cap screws and nuts securing the
steering shaft housing to the steering support; then
remove the cap screw securing the intermediate shaft
yoke to the steering shaft.

1. Remove the steering wheel cover; then match mark
the steering shaft and steering wheel.
NOTE: Any time steering components are disassembled, all connecting components should be
marked for proper alignment during assembling.

2. Remove the lock clip from the steering shaft; then
remove the nut securing the steering wheel and
remove the steering wheel.
INSPECTING
1. Inspect the steering wheel for cracks, missing padding, or broken spokes.

PR764A

2. Inspect the splines for wear.
3. Check that the steering wheel is not bent.
INSTALLING
1. Install the steering wheel aligning the two match
marks; then apply a drop of red Loctite #271 to the
threads of the nut and secure the steering wheel.
Tighten to 25 ft-lb.
NOTE: If a new steering wheel is being installed,
mark the wheel as close as possible to the old
wheel mark; then check for proper positioning with
the front wheels straight forward.

2. Install the lock clip on the steering shaft.

PR765A

3. Remove the steering shaft housing and shaft from the
steering support and intermediate shaft; then remove
the intermediate shaft from the EPS input shaft.
21

NOTE: Any time steering components are disassembled, all connecting components should be
marked for proper alignment during assembling.

INSPECTING
1. Inspect the steering wheel shaft for excessive wear.
2. Check for worn splines, cracks, or damaged threads.
3. Roll the steering wheel shaft on a flat surface to
check for bends.
4. Inspect the nylon bushings in the steering shaft housing for cracking or excessive wear.
INSTALLING
1. Install the steering shaft housing with steering shaft connecting the steering shaft and intermediate shaft first;
then slide the housing into place on the steering support.
2. Secure the steering shaft housing to the frame with
four cap screws and nuts. Tighten the 6 mm nuts to 8
ft-lb and the 8 mm nuts to 20 ft-lb.

Intermediate Steering
Shaft Assembly
AT THIS POINT
Before beginning this procedure, the upper steering shaft
must be removed.

REMOVING
With the upper steering shaft removed, remove the cap
screw from the intermediate shaft coupler and remove the
shaft from the EPS and vehicle.
INSPECTING
NOTE: The lower steering shaft assembly is not
repairable or rebuildable. If any damage or excessive wear is detected, the assembly must be
replaced.

1. Inspect the joints for excessive wear or looseness.
2. Inspect welds.
INSTALLING
1. Place the steering shaft assembly into position
through the opening in the splash panel; then align
the slot in the intermediate steering shaft coupler to
the index (flattened) spline on the EPS input shaft
and install. Install but do not tighten the cap screw.

PR764B

3. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb.

PR759B

2. Install the steering shaft housing with steering shaft
connecting the steering shaft and intermediate shaft
first; then slide the housing into place on the steering
support.
PR765A

3. Secure the steering shaft housing to the frame with
four cap screws and nuts. Tighten the 6 mm nuts to 8
ft-lb and the 8 mm nuts to 20 ft-lb.

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.

PR764B

4. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb; then tighten the cap screw
(from step 1) to 11 ft-lb.
PR193

8. Tap the ball joint end out of the knuckle; then
remove the knuckle.
9. Remove the snap ring securing the bearing in the
knuckle; then press the bearing out of the knuckle.

PR765A

5. Install the dash and connect the two electrical connectors. Secure with sheet metal screws and tighten
securely. Do not over-tighten.
6. Install the steering housing boot; then install the boot
support and secure with two machine screws.
7. Install the steering wheel; then apply a drop of red
Loctite #271 to the threads of the castle nut. Secure
the steering wheel and tighten to 25 ft-lb. Install the
lock clip and cover.

Steering Knuckles
REMOVING AND DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.

! WARNING

PR289

CLEANING AND INSPECTING
1. Clean all knuckle components.
2. Inspect the bearing for pits, scoring, rusting, or premature wear.
3. Inspect the knuckle for cracks, breaks, or galling of
the bearing surface.
ASSEMBLING AND INSTALLING
1. Using a suitable press and driver, press the bearing
into the knuckle until firmly seated; then install the
snap ring.

Make sure the vehicle is solidly supported on the support stand to avoid injury.

2. Remove the cotter pin from the axle.
3. Remove the nut securing the hub.
4. Remove the brake caliper.
5. Remove the hub assembly.

NOTE: During assembling, new cotter pins
should be installed.

4. Apply a small amount of grease to the hub splines.

PR292A

PR290A

5. Install the hub assembly onto the splines of the shaft.

PR289

2. Install the knuckle to the upper and lower ball joints
and secure with the two cap screws. Tighten to 35 ftlb.

CD009

6. Secure the hub assembly with the nut. Tighten to 200
ft-lb.

PR202

PR256

7. Install a new cotter pin and secure by spreading as
shown.

PR203

3. Install the tie rod end and secure with the nut (coated
with red Loctite #271). Tighten to 30 ft-lb; then
install a new cotter pin and spread the pin.
24

PR260

NOTE: If the hole in the axle shaft does not align
with the slots in the castle nut, tighten the nut until
the hole and slots align.

8. Secure the brake caliper to the knuckle with the two
new “patch-lock” cap screws. Tighten to 20 ft-lb.

HDX256

INSTALLING
Align the mounting holes with the holes in the splash
panel and secure with the two torx-head screws and nuts;
then snap the throttle cable holding grommet into the
actuator arm.

Shift Lever
REMOVING
1. Remove the dashboard (see Dashboard in this section).

PR377B

2. Remove the nut securing the shift cable to the shift
arm; then remove the four cap screws securing the
shift axle supports to the frame and remove the shift
lever.

9. Install the wheel; then using a crisscross pattern,
tighten in 20 ft-lb increments to 80 ft-lb.
10. Remove the vehicle from the support stand.

Accelerator Pedal
REMOVING
Dislodge the throttle cable holding grommet from the
actuator arm; then remove two torx-head screws and nuts
securing the accelerator pedal assembly to the splash
panel and remove the accelerator pedal.

HDX166A

HDX168A
PR709

INSTALLING
1. Install the shift axle supports onto the shift lever;
then secure the axle supports to the frame with four
cap screws and tighten to 48 in.-lb.

3. Tilt the cargo box back and remove the E-clip from
the shift arm on the transmission; then loosen the
adjuster nut on the shift cable housing and remove
the shift cable from the transmission.

HDX137B

2. Secure the shift cable end to the shift arm stud with
the cap screw and nut. Tighten to 8 ft-lb.

4. Remove the center floorboard and remove all nylon
ties securing the cable housing to the frame; then
remove the shift cable.

Shift Cable

NOTE: If the cable is being replaced, connect the
new cable to the end of the cable being removed and
pull the new cable into place.

HDX168

REMOVING
1. Remove the dashboard (see Dashboard in this section).
2. Remove the nut securing the shift cable to the shift
arm stud; then loosen the upper adjuster nut on the
shift cable and remove the shift cable from the shifter
assembly.

HDX132A

INSTALLING
1. Route the cable into position making sure there are
no kinks or sharp bends.
2. Install the cable housing onto the transmission
holder; then connect the cable end to the shift arm
and secure with the E-clip.
HDX166A

3. Install the shift cable into the shift cable support;
then connect the shift cable end to the shifter and
secure with a cap screw and nut. Tighten to 8 ft-lb.
4. Adjust the shift cable (see Periodic Maintenance Shift Lever).
5. Install nylon ties on the shift cable where removed;
then install the center floorboard and tighten the
machine screws securely.
6. Install the dashboard (see Dashboard in this section).

HDX178A

7. Shift the transmission through all positions making
sure the gear position icons indicate the appropriate
gears selected and that the Park Indicator illuminates
only when fully in Park. (See Periodic Maintenance Shift Lever).

LCD Gauge/Indicator
Lights
REPLACING
1. Remove the steering wheel; then remove the steering
wheel boot.
2. Remove the two machine screws securing the steering wheel boot support to the steering support assembly. Remove the boot support.

PR284A

6. Place the new gauge into the dash panel opening;
then place the gauge holder over the mounting
screws and secure with the nuts.
7. Plug the multi-pin connector into the gauge; then
turn the ignition switch to the ON position and check
gauge functions.
8. Slide the dash into position and secure with the six
screws.
9. Install the shifter handle; then install the shift lever
boot.
10. Install the steering wheel boot support.

PR762A

3. Remove the six screws securing the dash panel to the
frame; then remove the shifter handle and shift lever
boot.
4. Slide the dash panel to the rear sufficiently to access
the components.
PR762A

11. Install the steering boot onto the boot support.
12. Install the steering wheel; then with a drop of red
Loctite #271 on the threads of the steering shaft,
install the nut and tighten to 25 ft-lb.
13. Install the lock clip and steering wheel cover.

PR181A

5. Remove the nuts securing the gauge assembly to the
dash; then unplug the multi-pin connector and
remove the gauge from the vehicle.

HDX131A

Checking/Adjusting Front
Wheel Alignment
NOTE: All measurements and adjustments must
be made with the vehicle unloaded.

CAUTION
Always use a wrench to hold the tie rod ends when loosening or tightening the jam nuts or damage to the boots
could occur.

2. Turn the left-side and right-side tie rods in equal
increments to achieve the proper toe-out; then
tighten the jam nuts securely.

Mark the center-line of the front tires at the front and rear
of the tire; then using a tape measure, measure and record
the distance between the marks at the front and rear. The
front measurement should be 6-12 mm (1/4-1/2 in.)
greater than the rear measurement (toe-out).

PR086

Front Bumper Assembly
PR087A

To adjust the wheel alignment, use the following procedure.
1. Center the steering wheel; then using an open-end
wrench to hold the tie rod ends, loosen the right-side
and left-side jam nuts.

REMOVING
Remove four cap screws and nuts. Account for four lock
washers and eight flat washers.

PR327A
HDX098B

CLEANING AND INSPECTING
1. Clean all bumper components with hot, soapy water.
2. Inspect all welds for cracking or bending.
INSTALLING
Place the bumper assembly into position on the frame;
then secure with the four cap screws and nuts making
sure the flat washers and lock washers are properly positioned. Tighten securely.

PR085A

Hood
REMOVING
1. Open the hood; then disconnect the four headlight
connectors and remove two nylon ties.

PR332

3. Connect the four headlight connectors; then secure
the wires with two new nylon ties.

PR328A

2. Loosen but do not remove the four cap screws and
flange nuts securing the hood hinge to the frame;
then lower the hood.

PR332B

Fenders
REMOVING

PR332A

Remove three torx-head screws securing each fender to
the frame. Account for a stiffener bracket on the front
fenders.

3. Finish removing the cap screws and flange nuts
(from step 2); then remove the hood assembly.
CLEANING AND INSPECTING
1. Clean all hood components with soap and water.
2. Inspect the hood for cracks and/or loose fasteners.
3. Inspect for any missing decals.
INSTALLING
1. Place the hood into position on the vehicle; then
install the two outside cap screws and flange nuts.
Finger-tighten only at this time.
2. Open the hood; then install the remaining two cap
screws and flange nuts. Tighten all four securely.

PR311A

INSTALLING
Place the appropriate fender into position and secure with
existing hardware.

5. From the opposite side of the vehicle, repeat step 3;
then lift the rear of the floor up and lift the floor out
of the vehicle.

Floor

CLEANING AND INSPECTING
REMOVING

1. Clean the floor with soap and water.

1. Remove the seat, seat back, and seat base.

2. Inspect the floor for cracks or holes.

2. Remove the self-tapping screws securing the side
foot restraints.
3. Remove the center floorboard.

INSTALLING
1. Place the front of the floor into position in the vehicle first; then lower the rear and push past the seat
locating studs.
2. Secure the floor with the cap screws and self-tappings screws.
3. Install the center floorboard; then install the seat
base, seat back, and seat.

Dashboard
REMOVING
HDX132A

4. While pulling forward on the upper-rear of the floor,
lift the rear part of the floor above the seat locating
stud.

1. Remove the steering wheel and steering shaft
boot.
2. Remove two machine screws securing the steering
shaft boot support to the steering support and
remove the boot support.

PR163

NOTE: To aid in removing, insert a small wood
block to hold in position.

PR762A

3. Remove the six sheet metal and three machine
screws securing the dash assembly to the frame;
then remove the shift lever grip and locking nut.
4. Disconnect the gauge plug, dash harness, and
park/seat belt indicator light connector and remove
the dash assembly.
5. Slide the dash assembly rearward and off the steering shaft and shift lever assemblies.
INSTALLING

PR164

1. Place the dash into position and connect the park/
seat belt indicator light, dash harness, and gauge
connector.

2. Secure the dash with the six sheet metal and three
machine screws. Do not over-tighten.

NOTE: For additional details on cleaning the muffler/spark arrester, see the Periodic Maintenance.

3. Install the steering shaft boot support and secure
with machine screws; then install the steering shaft
boot and steering wheel. Apply a drop of red Loctite #271 to the steering shaft; then tighten the
steering wheel nut to 25 ft-lb and install the lock
clip.

INSTALLING MUFFLER
1. Place the muffler onto the holder pins and slide into
position.
2. Secure the muffler to the exhaust pipe with the two
exhaust springs.

4. Install the steering wheel cover.
5. Check shifter/shift cable adjustment (see Periodic
Maintenance - Shift Lever).

Cargo Box
REMOVING

Belly Panel

1. Raise the cargo box; then remove the cap screw and
nut securing the lower lift support to the frame.
Account for the washer. The cargo box will tilt fully
rearward.

REMOVING
1. Remove the body screws securing the belly panel to
the underside of the frame.
2. Remove the belly panel.
INSTALLING
1. Place the belly panel into position on the underside
of the frame.
2. Install the body screws. Tighten securely.

Exhaust System
HDX257

2. Loosen but do not remove the four shoulder cap
screws securing the pivot housings to the cargo box.

REMOVING MUFFLER
1. Remove the two exhaust springs at the muffler/
exhaust pipe juncture.

PR335

PR131

2. Slide the muffler assembly clear of the holder pins.
INSPECTING MUFFLER
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.

3. Lower the cargo box; then remove the four cap
screws (from step 2).
4. With the help of an assistant or an adequate lift,
remove the cargo box from the vehicle. Account for
four pivot housings.
CLEANING AND INSPECTING
1. Clean all cargo box components with soap and water.
2. Inspect the cargo box for cracks, tears, and loose
hardware.
31

3. Inspect the welds of the cargo box frame for cracking
or bending.
4. Inspect the cargo box gate latches for smooth operation.
INSTALLING
1. With the help of an assistant or an adequate lift, set
the cargo box into position on the frame; then position the two upper pivot housings between the cargo
box and frame. Lightly grease the pivot housings.
2. Align the holes in the upper pivot housings with the
holes in the cargo box; then install the lower pivot
housings and secure with the four shoulder cap
screws. Tighten to 20 ft-lb.
3. Raise the cargo box; then connect the lift support to
the frame, install the cap screw and nut, and tighten
the nut securely.
4. Lower the cargo box and lock into position.

Taillight Assembly
REMOVING
1. Remove the cap screws and lock nuts securing the
taillight assembly to the ROPS tube.

2. Disconnect the wire connector; then remove the
socket assembly and remove the bulb.
INSPECTING
1. Inspect wiring harness, three-prong connector, lens,
base, cap screws, and socket for damage.
2. Inspect all wires for corroding, pinching, and cracking.
3. Inspect the bulb for wattage, voltage, and proper
operation.
INSTALLING
1. Install the new bulb in the socket and place the
socket assembly into the taillight housing. Twist
clockwise to lock.
2. Connect the wire connector; then install on the
ROPS tube and secure with two cap screws and lock
nuts. Tighten securely.

Seat
REMOVING/INSTALLING
1. To remove the seat, raise the front of the seat and
slide it forward.
2. To install the seat, slide the rear of the seat into the seat
retainers and push down firmly on the front of seat.

Troubleshooting
Problem: Handling too heavy or stiff
Condition
1.
2.
3.
4.
5.

Front wheel alignment incorrect
Steering shaft binding
Tire inflation pressure incorrect
Tie rod ends seizing
U-joints seized

Problem: Steering oscillation
Condition
1.
2.
3.
4.
5.
6.
7.
8.

Tires inflated unequally
Wheel(s) bent
Wheel hub studs loose - missing
Wheel hub bearing worn - damaged
Tie rod ends worn - loose
Tires defective - incorrect
A-arm bushings damaged
Bolts - nuts (frame) loose

Problem: Steering pulling to one side
Condition
1.
2.
3.
4.
5.

Tires inflated unequally
Front wheel alignment incorrect
Wheel hub bearings worn - broken
Frame distorted
Shock absorber defective

Problem: Steering impaired
Condition
1. Tire pressure too high
2. Steering linkage worn
3. Cap screws (suspension system) loose

Problem: Tire wear rapid or uneven
Condition
1. Wheel hub bearings worn - loose
2. Front wheel alignment incorrect

Problem: Steering noise
Condition
1. Caps screws - nuts loose
2. Wheel hub bearings broken - damaged
3. Lubrication inadequate

Problem: Rear wheel oscillation
Condition
1.
2.
3.
4.
5.
6.
7.

Rear wheel hub bearings worn - loose
Tires defective - incorrect
Wheel rim distorted
Wheel hub cap screws loose
Rear suspension arm-related bushing worn
Rear shock absorber damaged
Rear suspension arm nut loose

Remedy
1.
2.
3.
4.
5.

Adjust alignment
Lubricate/replace steering shaft
Adjust pressure
Replace tie rod ends
Replace U-joints

Remedy
1.
2.
3.
4.
5.
6.
7.
8.

Adjust pressure
Replace wheel(s)
Tighten - replace wheel studs
Replace bearing
Replace - tighten tie rod ends
Replace tires
Replace bushings
Tighten bolts - nuts

Remedy
1.
2.
3.
4.
5.

Adjust pressure
Adjust alignment
Replace bearings
Repair - replace frame
Replace shock absorber

Remedy
1. Adjust pressure
2. Replace linkage
3. Tighten cap screws

Remedy
1. Replace bearings
2. Adjust alignment

Remedy
1. Tighten cap screws - nuts
2. Replace bearings
3. Lubricate appropriate components

Remedy
1.
2.
3.
4.
5.
6.
7.

Replace bearings
Replace tires
Replace rim
Tighten cap screws
Replace bushing
Replace shock absorber
Tighten nut

SPECIAL TOOLS

Engine/Transmission
This section has been organized into sub-sections which
show a progression for the complete servicing of the Arctic Cat ROV engine/transmission.
To service the center crankcase halves, the engine/transmission must be removed from the frame. To service topside, left-side, and right-side components, the engine/
transmission does not have to be removed from the
frame.
NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal
components when servicing the engine/ transmission.
NOTE: A new ATV and an overhauled ATV engine
require a “break-in” period. The first 10 hours (or 200
miles) are most critical to the life of this ATV. Proper
operation during this break-in period will help assure
maximum life and performance from the ATV. Instruct
the customer to follow the proper break-in procedure
as described in the Operators Manual.

p/n
0444-252
0444-152

Magneto Rotor Remover Set
Piston Pin Puller
Secondary Drive Gear Holder

0444-254

Spanner Wrench
Surface Plate
V Blocks

0444-240

0644-328
0444-253
0644-016
0644-535

NOTE: Special tools are available from the Arctic
Cat Service Department.

Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Condition
Remedy
1.
2.
3.
4.
5.
6.

Valve clearance out of adjustment
Valve guides worn
Valves mistimed
Piston rings worn - broken
Cylinder bore worn
Starter motor cranks too slowly - does not turn

1.
2.
3.
4.
5.
6.

Adjust clearance
Replace guides
Retime engine
Replace rings
Replace cylinder
See Electrical System

Problem: Engine will not start or is hard to start (No spark)
Condition
Remedy
1.
2.
3.
4.
5.
6.

Spark plug fouled
Spark plug wet
Magneto defective
ECM defective
Ignition coil defective
High-tension lead open - shorted

1.
2.
3.
4.
5.
6.

Clean - replace plug
Clean - dry plug
Replace stator coil
Replace ECM
Replace ignition coil
Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Condition
Remedy
1.
2.
3.
4.

Gas tank vent hose obstructed
Fuel hose obstructed
Fuel screens obstructed
Fuel pump defective

Problem: Engine stalls easily
Condition
1.
2.
3.
4.
5.

Spark plug fouled
Magneto defective
ECM defective
Fuel injector obstructed
Valve clearance out of adjustment

Problem: Engine noisy (Excessive valve chatter)
Condition
1.
2.
3.
4.

Valve clearance excessive
Valve spring(s) weak - broken
Rocker arm - rocker arm shaft worn
Camshaft worn

1.
2.
3.
4.

Clean vent hose
Clean - replace hose
Clean - replace inlet screen
Replace fuel pump

Remedy
1.
2.
3.
4.
5.

Clean - replace plug
Replace stator coil
Replace ECM
Replace fuel injector
Adjust clearance

Remedy
1.
2.
3.
4.

Adjust clearance
Replace spring(s)
Replace arm - shaft
Replace camshaft

Problem: Engine noisy (Noise seems to come from piston)
Condition
Remedy
1.
2.
3.
4.

Piston - cylinder worn
Combustion chamber carbon buildup
Piston pin - piston pin bore worn
Piston rings - ring groove(s) worn

1.
2.
3.
4.

Replace cylinder - service piston
Clean cylinder head and piston
Replace - service pin - bore
Replace rings - piston

Problem: Engine noisy (Noise seems to come from timing chain)
Condition
Remedy
1. Chain stretched
2. Sprockets worn
3. Tension adjuster malfunctioning

1. Replace chain
2. Replace sprockets
3. Repair - replace adjuster

Problem: Engine noisy (Noise seems to come from crankshaft)
Condition
Remedy
1.
2.
3.
4.
5.

Main bearing worn - burned
Lower rod-end bearing worn - burned
Connecting rod side clearance too large
Centrifugal clutch loose
Rotor/flywheel loose

1.
2.
3.
4.
5.

Replace bearing
Replace crankshaft assembly
Replace crankshaft assembly
Tighten - replace clutch
Tighten - replace flywheel - crankshaft

Problem: Engine noisy (Noise seems to come from transmission)
Condition
Remedy
1.
2.
3.
4.
5.

Gears worn - chipped
Splines worn
Primary gears worn - chipped
Bearings worn
Bushing worn

1.
2.
3.
4.
5.

Replace gears
Replace shaft(s) - gears
Replace gears
Replace bearings
Replace bushing

Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition
Remedy
1.
2.
3.
4.
5.
6.
7.

Drive - driven bevel gears damaged - worn
Backlash excessive
Tooth contact improper
Bearing damaged
Gears worn - chipped
Splines worn
Final driven shaft thrust clearance too large

Problem: Engine idles poorly
Condition
1.
2.
3.
4.
5.
6.
7.
8.
9.

Valve clearance out of adjustment
Valve seating poor
Valve guides defective
Rocker arms - arm shaft worn
Magneto defective
ECM defective
Spark plug fouled - gap too wide
Ignition coil defective
Fuel injector obstructed

Problem: Engine runs poorly at high speed
Condition
1.
2.
3.
4.
5.
6.
7.
8.

High RPM “cut out” against RPM limiter
Valve springs weak
Valve timing out of adjustment
Cams - rocker arms worn
Spark plug gap too narrow
Ignition coil defective
Air cleaner element obstructed
Fuel hose obstructed

Problem: Exhaust smoke dirty or heavy
Condition
1.
2.
3.
4.
5.
6.

Engine oil overfilled - contaminated
Piston rings - cylinder worn
Valve guides worn
Cylinder wall scored - scuffed
Valve stems worn
Stem seals defective

1.
2.
3.
4.
5.
6.
7.

Replace gears
Adjust backlash
Adjust contact
Replace bearing
Replace gears
Replace shaft(s) - gears
Replace thrust washer(s)

Remedy
1.
2.
3.
4.
5.
6.
7.
8.
9.

Adjust clearance
Replace - service seats - valves
Replace guides
Replace arms - shafts
Replace stator coil
Replace ECM
Adjust gap - replace plug
Replace ignition coil
Replace fuel injector

Remedy
1.
2.
3.
4.
5.
6.
7.
8.

Shift into higher gear - decrease speed
Replace springs
Adjust timing
Replace cams - arms
Adjust gap
Replace ignition oil
Clean element
Clean - prime hose

Remedy
1.
2.
3.
4.
5.
6.

Drain excess oil - change oil
Replace cylinder - service rings
Replace guides
Replace cylinder
Replace valves
Replace seals

Problem: Engine lacks power
Condition

Remedy

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Valve clearance incorrect
Valve springs weak
Valve timing out of adjustment
Piston ring(s) - cylinder worn
Valve seating poor
Spark plug fouled
Rocker arms - shafts worn
Spark plug gap incorrect
Fuel injector obstructed
Air cleaner element obstructed
Engine oil overfilled - contaminated
Intake manifold leaking air
Cam chain worn

Adjust clearance
Replace springs
Time camshaft
Replace cylinder - service rings
Repair seats
Clean - replace plug
Replace arms - shafts
Adjust gap - replace plug
Replace fuel injector
Clean element
Drain excess oil - change oil
Tighten - replace manifold
Replace cam chain - sprockets

Problem: Engine overheats
Condition

Remedy

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Carbon deposit (piston crown) excessive
Oil low
Octane low - gasoline poor
Oil pump defective
Oil circuit obstructed
Intake manifold leaking air
Coolant level low
Fan malfunctioning
Fan relay malfunctioning
Thermostat stuck - closed
Radiator hoses - cap damaged - obstructed

Clean piston
Add oil
Drain - replace gasoline
Replace pump
Clean circuit
Tighten - replace manifold
Fill - examine system for leaks
Check fan fuse/fan relay - replace fan
Replace fan relay
Replace thermostat
Clear obstruction - replace hoses

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.

AT THIS POINT
If the technician’s objective is to service/replace rightside cover oil seals, front output joint oil seal, rear output joint oil seal, and/or the oil strainer (from beneath
the engine/transmission), the engine/transmission does
not have to be removed from the frame.

HDX138A

6. Loosen the clamp securing the air filter intake tube to
the air filter; then remove the mounting screw and
remove the intake tube.

Support the vehicle on a suitable lift or jack stands allowing room to perform work from the underside.
NOTE: Locate the jack stands to allow removing
of the center belly panel.

! WARNING
Make sure the vehicle is solidly supported on the support stands to avoid injury.

1. Remove the seat, seat back, and seat base; then
disconnect negative battery cable.
2. Remove the center skid plate; then drain the oil
and coolant.
3. Remove the center floorboard.
4. Marking all nylon tie locations for installing purposes, from the right side disconnect the MAP
sensor connector (A), fuel injector connector (B),
ISC connector (C), and TPS connector (D).

HDX031A

7. Remove four sheet metal screws securing the air filter mounting bracket to the frame; then loosen the air
inlet boot clamp and disconnect the IAT sensor connector and remove the air filter assembly.

HDX148A

HDX136A

5. Wrap the gasline hose connector with a shop cloth;
then remove the gasline hose connector from the
fuel rail.

! WARNING
Gasoline may be under pressure. Place an absorbant
towel around the connector to absorb any gasoline
spray when disconnected.
HDX144A

8. Loosen the clamp securing the throttle body to the
intake manifold boot; then remove the throttle body
and set aside.

700

9. From the left side, disconnect the ECT sensor connector, speed sensor connector, and spark plug cap.

HDX251

NOTE: On the 500, shifting the transmission into
park will aid in accessing the shift arm cap screw.

HDX135A

11. Disconnect the starter cable from the starter; then
remove the cap screw securing the engine/harness
ground wires to the engine case.

HDX137A

10. Remove the cap screws securing the shift cable
bracket to the engine case. Remove the cap screw
from the shift arm and disconnect the gear position
switch connector. Slide the gear position switch off
the engine.

HDX149A

12. Remove the CVT inlet and exhaust ducts from the
V-belt housing.

500

HDX146A
HDX254

15. Remove the two exhaust springs at the muffler; then
remove the exhaust pipe. Account for a grafoil seal
in the cylinder head and a grafoil seal at the muffler.

HDX147A

13. Remove the forward heat shield from the exhaust
pipe; then remove the cap screws securing the
exhaust pipe to the cylinder head.

HDX153A

16. Remove the cap screws securing the driveshafts to
the front and rear engine flanges; then disconnect
the upper and lower coolant hoses.

HDX152A

HDX158A

HDX154

14. Disconnect the O2 sensor; then remove the O2 sensor.

HDX159A

17. Disconnect the oil cooler lines and plug them to
prevent oil spillage.
18. Remove the nuts from the rear engine mounts;
then remove the front through-bolt.

HDX247

Top-Side Components
NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

AT THIS POINT
HDX157A

To service any one specific component, only limited disassembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to
removed from the frame for this procedure.

Removing Top-Side
Components

HDX156A

19. Attach a suitable lifting sling and with a suitable
engine hoist, lift the engine from the vehicle.

Servicing Engine (500)
Top-Side Components ....................................................... 40
Removing Top-Side Components ...................................... 40
Servicing Top-Side Components ....................................... 44
Installing Top-Side Components ........................................ 51
Left-Side Components ....................................................... 54
Removing Left-Side Components ...................................... 54
Servicing Left-Side Components ....................................... 57
Installing Left-Side Components ........................................ 59
Right-Side Components..................................................... 61
Removing Right-Side Components.................................... 61
Servicing Right-Side Components..................................... 64
Installing Right-Side Components...................................... 65
Center Crankcase Components......................................... 68
Separating Crankcase Halves ........................................... 69
Disassembling Crankcase Half .......................................... 69
Servicing Center Crankcase Components......................... 71
Assembling Crankcase Half............................................... 76
Joining Crankcase Halves ................................................. 78

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
appropriate wrench, rotate the crankshaft to topdead-center of the compression stroke.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the engine/
transmission.

1. Remove the cap screws securing the two tappet covers. Remove the two tappet covers. Account for the
O-rings.

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.

FI608

4. Bend the washer tabs and remove the two cap screws
securing the sprocket to the camshaft.

FI606A

FI612

5. Using an awl, rotate the C-ring in its groove until it is
out of the cylinder head; then remove the C-ring.
MD1354A

3. Remove the cap screw from the tension adjuster;
then using a flat-blade screwdriver, relax the cam
chain tension by rotating the adjuster screw clockwise until it locks.

FI613

NOTE: Care should be taken not to drop the Cring down into the crankcase.
FI607A

MD1131

FI616

6. Noting the timing marks for installing purposes, drop
the sprocket off the camshaft. While holding the cam
chain, slide the sprocket and camshaft out of the cylinder head. Account for an alignment pin.
NOTE: Loop the chain over the cylinder and
secure it to keep it from falling into the crankcase.

FI617

FI620

FI618A

FI617A

7. Remove the cam chain tensioner pivot bolt and
remove the chain tensioner; then remove the two
nuts securing the cylinder head to the cylinder.

FI619A

8. Remove the four cylinder head cap screws and washers. Note that the two cap screws on the right side of
the cylinder head nearest the cam sprocket are longer
than the two cap screws on the left (spark plug) side.

CD211

FI622A

9. Remove the cylinder head from the cylinder, remove
the gasket, and account for two alignment pins.

12. Lift the cylinder off the crankcase taking care not to
allow the piston to drop against the crankcase.
Account for the gasket and two alignment pins.

FI623A
FI624A

AT THIS POINT
To service valves and cylinder head, see Servicing TopSide Components sub-section.

10. Remove the cam chain guide.

AT THIS POINT
To service cylinder, see Servicing Top-Side Components sub-section.

CAUTION

AT THIS POINT
To inspect cam chain guide, see Servicing Top-Side
Components sub-section.

When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston.

13. Using an awl, remove one piston-pin circlip. Take
care not to drop it into the crankcase.

FI621

C. Cylinder
D. Piston
NOTE: Steps 1-10 in the preceding sub-section
must precede this procedure.

11. Remove the two nuts securing the right side of the
cylinder to the right-side crankcase half.

FI625

14. Using Piston Pin Puller, remove the piston pin.
Account for the opposite-side circlip. Remove the
piston.
NOTE: It is advisable to remove the opposite-side
circlip prior to using the puller.

CAUTION
Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always
check camshaft clearance when resurfacing the cylinder head cover.

MD1219

NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install a connecting rod holder.

CAUTION
Do not allow the connecting rod to go down inside the
crankcase. If the rod is down inside the crankcase and
the crankshaft is rotated, severe damage will result.

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.

Servicing Top-Side
Components

CC130D

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

Removing Valves
NOTE: Index all valves, springs, and cotters to
their original position when removing. When
installing, all valve components should be
installed in their original position.

1. Using a valve spring compressor, compress the valve
springs and remove the valve keepers. Account for an
upper spring retainer.

VALVE ASSEMBLY

When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it
must be replaced.

Cleaning/Inspecting 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 figure eight motion. Inspect the sealing surface for any
indication of high spots. A high spot can be noted by
a bright metallic finish. Correct any high spots
before assembly by continuing to move the cylinder
head cover in a figure eight motion until a uniform
bright metallic finish is attained.
44

CC132D

2. Remove the valve seal and the lower remaining spring
seat. Discard the valve seal.

Measuring Valve Face/Seat Width
1. Using a calipers, measure the width of the valve face.

CC134D

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

ATV1082A

3. Rotate the valve in the V blocks.
4. Maximum runout 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.
ATV-1082

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 components be taken to a qualified machine shop for servicing.

CAUTION
If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt
to grind the valves or severe engine damage may occur.

4. Place a spring retainer over the valve springs; then
using the valve spring compressor, compress the
valve springs and install the valve keepers.

Measuring Rocker Arm
(Inside Diameter)
1. Using a dial calipers, measure the inside diameter of
the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)

CC132D

1. Using a micrometer, measure the outside diameter of
the rocker arm shaft.

PISTON ASSEMBLY

2. Acceptable outside diameter range must be within
specifications.

NOTE: Whenever a piston, rings, or pin are out of
tolerance, they must be replaced.

Installing Valves

Cleaning/Inspecting Piston

1. Apply grease to the inside surface of the valve seals;
then place a lower spring seat and valve guide seal
over each valve guide.

1. 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.

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.

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
complete set only.

ATV-1011A

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.

2. Inspect and measure the connecting rod small end
inside diameter. If the measurement exceeds specifications, the connecting rod must be replaced (see
Center Crankcase Components in this section).
3. Insert an inside dial indicator into the piston-pin
bore. Take two measurements to ensure accuracy.
The diameter must not exceed specifications. If the
diameter exceeds specifications, the piston must be
replaced.

CAUTION
Improper cleaning of the ring grooves by the use of the
wrong type of ring groove cleaner will result in severe
damage to the piston.

Measuring Piston-Ring End Gap
(Installed)
1. Place each piston ring in the wear portion of the cylinder. Use the piston to position each ring squarely in
the cylinder.
2. Using a feeler gauge, measure each piston-ring end
gap. Acceptable ring end gap must not exceed specifications.

ATV-1069

Measuring Piston Skirt/
Cylinder Clearance
1. Measure the cylinder front to back in six places.

CC995

Measuring Piston Pin, Connecting
Rod Small End, and Piston-Pin Bore
CC127D

1. Measure the piston pin outside diameter at each end
and in the center. If measurement does not meet
specifications, the piston pin must be replaced.

2. Measure the corresponding piston diameter at a point
8 mm (0.3 in.) above the piston skirt at a right angle
to the piston-pin bore. Subtract this measurement
from the measurement in step 1. The difference
(clearance) must be within specifications.
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of the
piston; then install the thin oil rings (3) over the
expander making sure the expander ends do not
overlap. Stagger the end gaps of the upper and lower
thin oil rings according to the illustration.
NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.

ATV-1070

3. Place the cylinder head on the surface plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder head in a figure eight
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic
finish is attained.

CAUTION

ATV-1085B

2. Install the compression rings (1 and 2) so the letter(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.

Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

Measuring Cylinder Head Distortion
1. Remove any carbon buildup in the combustion
chamber.
2. Lay a straightedge across the cylinder head; then
using a feeler gauge, check the distortion factor
between the head and the straightedge.
3. Maximum distortion must not exceed specifications.

MD1343A

CAUTION
Incorrect installation of the piston rings will result in
engine damage.

CYLINDER/CYLINDER HEAD
ASSEMBLY
NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

CAUTION
The cylinder head studs must be removed for this procedure.

1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the combustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged threads.
Repair damaged threads using a “heli-coil” insert.

CC141D

Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning solvent.
2. Inspect the cylinder for pitting, scoring, scuffing,
warpage, and corrosion. If marks are found, repair
the surface using a cylinder hone (see Honing Cylinder in this sub-section).
3. Place the cylinder on the surface plate covered with
#400 grit wet-or-dry sandpaper. Using light pressure,
move the cylinder in a figure eight motion. Inspect
the sealing surface for any indication of high spots.
A high spot can be noted by a bright metallic finish.
Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion
until a uniform bright metallic finish is attained.

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

CC129D

CC390D

4. If any measurement exceeds the limit, the cylinder
must be replaced.

Inspecting Cam Chain Guide
1. Inspect cam chain guide for cuts, tears, breaks, or
chips.
2. If the chain guide is damaged, it must be replaced.
Honing Cylinder
1. Using a slide gauge and a dial indicator or a snap
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a total
of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness)
must not exceed specifications.

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 tolerance must not exceed specifications.
Measuring Camshaft Lobe Height
CC127D

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

2. Wash the cylinder in parts-cleaning solvent.
3. Inspect the cylinder for pitting, scoring, scuffing, and
corrosion. If marks are found, repair the surface
using a #320 grit ball hone.
NOTE: To produce the proper 60° cross-hatch
pattern, use a low RPM drill (600 RPM) at the rate
of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and
hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is
severely damaged or gouged, replace the cylinder.

ATV1013A

2. The lobe heights must be greater than minimum
specifications.

Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be replaced.
Measuring Camshaft to
Cylinder Head Clearance
1. Loosen the jam nuts and adjuster screws.
CC145D

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

CC005D

2. Place a strip of plasti-gauge in each of the camshaft
lands in the cylinder head.
3. Place the valve cover on the cylinder head and secure
with the valve cover cap screws. Tighten securely.
NOTE: Do not rotate the camshaft when measuring clearance.

4. Remove the cap screws securing the valve cover to
the cylinder; then remove the valve cover and camshaft.

CC287D

NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.

Inspecting Camshaft Spring/Drive
Pin
1. Inspect the spring and unloader pin for damage.

MD1261

5. Match the width of the plasti-gauge with the chart
found on the plasti-gauge packaging to determine
camshaft to cylinder head and valve cover clearance.

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.

CF060A

2. If damaged, the camshaft must be replaced.

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.

Installing Top-Side
Components

CAUTION
The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur.

A. Piston
B. Cylinder
1. Lubricate the piston pin, connecting rod, and piston pin
bore with motor oil; then install the piston on the connecting rod making sure there is a circlip on each side.

GZ142

4. Loosely install the two nuts securing the cylinder to
the right-side crankcase half.
FI626

NOTE: The piston should be installed so the IN
points towards the intake side.

NOTE: The two cylinder-to-crankcase nuts will be
tightened in step 9.

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.

FI622A

C. Cylinder Head/Camshaft
D. Cylinder Head Cover/
Rocker Arms

10. With the timing inspection plug removed and the cam
chain held tight, rotate the crankshaft until the piston is at
top-dead-center.

NOTE: Steps 1-4 in the preceding sub-section
must precede this procedure.

11. While holding the cam chain to the front, install the rear
cam chain tensioner guide into the cylinder head. Install
the pivot cap screw and washer. Tighten to 11 ft-lb.

5. While keeping tension on the cam chain, place the
front cam chain guide into the cylinder.

CAUTION
Care should be taken that the bottom of the chain guide
is secured in the crankcase boss.

CD383

12. With the alignment pin installed in the camshaft and the
cam lobes directed down (toward the piston), place the
camshaft in position and verify that the timing mark on
the magneto is visible through the inspection plug and
that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface.
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.

CAUTION
Keep tension on the cam chain to avoid damaging the
crankcase boss.

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.
MD1347

7. Install the four cylinder head cap screws with washers. Note that the two cap screws on the right side of
the cylinder head nearest the cam sprocket are longer
than the two cap screws on the left (spark plug) side.
Tighten only until snug.
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 ftlb.
52

CD463

16. Place the tab washer onto the sprocket making sure it
covers the pin in the alignment hole.

MD1359

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

MD1363

CAUTION
Care must be taken that the tab washer is installed correctly to cover the alignment hole on the sprocket. If the
alignment pin falls out, severe engine damage will
result.

17. Apply red Loctite #271 to the first cap screw securing the sprocket and tab washer to the camshaft; then
install the cap screw and tab washer. Tighten cap
screw only until snug.

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 valve 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.

CC404D

15. When the camshaft assembly is seated, ensure the
following.

A. Piston still at top-dead-center.
B. Camshaft lobes directed down (toward the piston).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
D. Recessed side of the sprocket directed toward
the cam lobes.
E. Camshaft alignment pin and sprocket alignment
hole (smallest) are aligned.

CAUTION
If any of the above factors are not as stated, go back to
step 13 and carefully proceed.

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 10 ft-lb; then bend
the tab to secure the cap screw.

19. Rotate the crankshaft until the first cap screw (from
step 17) securing the sprocket to the camshaft can be
addressed; then tighten to 10 ft-lb. Bend the tab to
secure the cap screw.

28. Place the two tappet covers with O-rings into position; then install and tighten the cap screws to 8.5 ftlb.

20. Install the cylinder head plug with the cupped end
facing the camshaft and the opening directed downwards.
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.

FI602

29. Install the spark plug and tighten securely; then
install the timing inspection plug.

Left-Side Components

FI608

23. Loosen the adjuster screw jam nuts; then loosen the
adjuster screws on the rocker arms in the valve
cover.

NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

AT THIS POINT

24. Apply a thin coat of Three Bond Sealant to the mating surface of the valve cover; then place the valve
cover into position. Note that the two alignment pins
are properly positioned.

To service any one specific component, only limited disassembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.

NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.

25. Install the four top-side cap screws with rubber
washers; then install the remaining cap screws.
Tighten only until snug.

Removing Left-Side
Components
A. 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.

MD1261

26. In a crisscross pattern starting from the center and
working outward, tighten the cap screws (from step
25) to 8.5 ft-lb.
27. Adjust valve/tappet clearance (see Periodic Maintenance).
54

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.

FI538

2. Remove the water pump housing assembly noting
the location of the longer cap screw. Account for a
gasket and two alignment pins.

FI543

5. Remove the cap screws securing the magneto cover
to the crankcase. Note the location of the two internal cap screws and the two longer cap screws.

FI539

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.
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.

7. Remove the nut securing the rotor/flywheel on the
crankshaft and install the crankshaft protector.

FI549
FI544

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.

FI559

12. Remove the shift detent cam arm and spring.

FI550

9. Remove the flywheel key from the crankshaft; then
remove the starter clutch gear.

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.
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.

FI564

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.

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 clockwise. 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.

FI570

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.

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

FI569

FI576A

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.

FI578

FI572

REPLACING STARTER CLUTCH
ASSEMBLY
1. Remove the cap screws securing the starter clutch
assembly to the flywheel; then remove from the flywheel.

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.

REPLACING STATOR COIL/
CRANKSHAFT POSITION SENSOR
1. Remove the three cap screws securing the stator coil,
two cap screws securing the crankshaft position sensor, 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.

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.

FI590

3. Install the new stator coil assembly and secure with three
cap screws. Tighten to 15 ft-lb.
4. Place the stator wire harness hold-down into position;
then install the crankshaft position sensor and secure
with two cap screws. Tighten securely.
FI580

5. Install the upper cable hold-down and secure with a cap
screw. Tighten securely.

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 discoloration, 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.

FI595A

REPLACING MAGNETO COVER
BEARINGS
1. Using a suitable press and proper support, press the
bearing from the housing as indicated (one from outside and one from inside).

FI588

FI593

MD1122

2. Install the starter motor and tighten the two cap
screws to 10 ft-lb.
3. Install the shift detent cam making sure the washer is
installed.

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.

MD1086

4. Install the shift detent cam arm and spring.
5. Install the gear shift shaft assembly and washer making sure to align the alignment marks.

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.
FI559

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

FI555A

FI547

7. Install the starter clutch gear onto the crankshaft;
then install the rotor/flywheel key in the crankshaft.

11. Install two alignment pins and a gasket on the magneto cover; then install the water pump housing
assembly. Tighten the cap screws to 8 ft-lb.

FI551A

8. Install the rotor/flywheel and secure with the nut.
Tighten to 107 ft-lb.

FI541A

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
the cap screws in a crisscross pattern to 8 ft-lb.
FI539

12. Install the water pump cover with a new O-ring and
secure with the four cap screws. Tighten to 8 ft-lb.

FI596A

10. Install the water pump drive gear and secure with the
nut. Tighten to 28 ft-lb.
FI538

13. Connect the coolant hoses to the water pump and
secure with the hose clamps. Tighten securely.

Right-Side Components
AT THIS POINT
To service center crankcase components only, proceed
to Removing Right-Side Components.

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.

AT THIS POINT
To service any one specific component, only limited disassembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.

Removing Right-Side
Components

MD1033

4. Remove the movable drive face and spacer. Account
for the movable drive face rollers and outer drive
face cover.

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 pedal axle.
Account for a flat washer.

MD1035

KC149A

2. Remove the cap screws securing the V-belt cover to
the clutch cover; then slide the brake pedal outward
and remove the V-belt cover. Account for two alignment pins and a gasket.

MD1034

8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate.
Remove the air intake plate.

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.

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.

KC132

6. Remove the fixed drive face.

MD1115

D. Centrifugal Clutch Assembly
E. Oil Pump Drive Gear
F. Oil Pump Driven Gear
NOTE: Steps 1-10 in the preceding sub-section
must precede this procedure.
MD1094

7. Remove the nut holding the driven pulley assembly;
then remove the driven pulley assembly.

MD1068

11. Remove the one-way clutch noting the direction of
the green dot or the word OUTSIDE for installing
purposes.

MD1286

12. Remove the left-hand threaded nut holding the centrifugal clutch assembly.

FI630

14. Remove the oil pump drive gear cap screw.

CAUTION
Care must be taken when removing the nut; it has “lefthand” threads.

MD1018

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

MD1014

MD1017

16. Remove the snap ring holding the oil pump driven
gear.
MD1016

13. Remove the cam chain.

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.

MD1337

MD1020

AT THIS POINT
To service clutch components, see Servicing Right-Side
Components sub-section.

G. Oil Pump/Oil Strainer
NOTE: Steps 1-17 in the preceding sub-sections
must precede this procedure.

18. Remove three cap screws holding the oil pump and
remove the oil pump. Account for two alignment
pins.

MD1208

AT THIS POINT
To service center crankcase components only, proceed
to Separating Crankcase Halves.

Servicing Right-Side
Components
INSPECTING CENTRIFUGAL CLUTCH
SHOE
Inspect the clutch shoe for uneven wear, chips, cracks, or
discoloration. If wear is present, replace the clutch
assembly.
MD1060

19. Remove the four cap screws securing the oil strainer
cap; then remove the Phillips-head screws securing
the oil strainer. Account for the O-ring.

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 assembly
with the green dot or the word “OUTSIDE” directed
away from the clutch shoe.

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 component and must be replaced as a complete assembly.

DRIVEN PULLEY ASSEMBLY
KC330

2. Place the clutch housing onto the clutch shoe/one-way
clutch.
NOTE: It will be necessary to rotate the clutch
housing counterclockwise to properly seat the
one-way clutch.

NOTE: The driven pulley assembly is a non-serviceable component and must be replaced as a
complete assembly.

Installing Right-Side
Components
A. Oil Strainer/Oil Pump
1. Place the oil strainer into position beneath the crankcase. Tighten the Phillips-head screws securely.

KC331A

3. Check that the clutch shoe can only be rotated counterclockwise in respect to the clutch housing. If the
clutch shoe locks up or turns in both directions, the
one-way clutch must be replaced.

MD1337

2. Place the strainer cap into position on the crankcase
making sure the O-ring is properly installed and
secure with the four cap screws. Tighten the cap
screws to 10 ft-lb; then install the oil drain plug and
tighten to 20 ft-lb.

MD1019

MD1208

3. Place two alignment pins and the oil pump into position on the crankcase and secure with the Phillipshead screws coated with red Loctite #271. Tighten to
8 ft-lb.

5. Install the cam chain.
NOTE: Keep tension on the cam chain to avoid
damaging the crankcase boss.

6. Place the pin into position, install the oil pump drive
gear, and tighten the cap screw (coated with red Loctite #271) to 63 ft-lb.

MD1060

4. Place the thrust washer and drive pin into position on
the oil pump shaft, install the oil pump driven gear
making sure the recessed side of the gear is directed
inward, and secure with a new snap ring.

MD1017

NOTE: Always use a new snap ring when installing the oil pump driven gear.

MD1018

7. Install the clutch shoe assembly on the crankshaft;
then install the flange nut (left-hand thread) (coated
with red Loctite #271). Tighten to 147 ft-lb.
MD1020

NOTE: The flat side of the flange nut should be
directed towards the clutch shoe.

CAUTION
Care must be taken when installing the flange nut; it has
“left-hand” threads.

8. Install the one-way clutch making sure that the green
dot or the word OUTSIDE is directed away from the
crankcase.

MD1342

MD1286

12. Place the driven pulley assembly into position and
secure with the nut (threads coated with red Loctite
#271). Tighten to 147 ft-lb.

B. Clutch Cover
C. Fixed Drive Face
D. Movable Drive Face
NOTE: Steps 1-8 in the preceding sub-section
must precede this procedure.

9. Install two alignment pins and place the clutch cover
gasket into position. Install the clutch cover.

MD1068

MD1115

10. Tighten the clutch cover cap screws to 8 ft-lb.
KC134

13. Slide the fixed drive face assembly onto the front
shaft.
14. Spread the faces of the driven pulley by threading a
V-belt cover cap screw into the fixed driven face and
tightening until the faces open sufficiently to allow
the V-belt to drop into the pulley approximately 3/4
in.

MD1117

11. Install the air intake plate. Apply red Loctite #271 to
the threads of the three Phillips-head cap screws;
then install and tighten securely.

KC137

KC141

NOTE: The arrows on the V-belt should point in
direction of engine rotation.

NOTE: At this point, the cap screw can be
removed from the driven pulley face.

15. 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.

17. Rotate the V-belt and drive/driven assemblies until
the V-belt is flush with the top of the driven pulley.
18. Install two alignment pins and place a new V-belt
cover gasket into position on the clutch cover. In a
crisscross pattern, tighten cap screws to 8 ft-lb.

KC127

16. Coat the threads of the nut with red Loctite #271;
then making sure the splines of the clutch shaft protrude through the cover plate, secure with the nut and
tighten to 147 ft-lb.

KC142A

19. If removed, install the brake pedal and tighten to 25
ft-lb.

KC138

Separating Crankcase
Halves
1. Remove the left-side and right-side cap screws
securing the crankcase halves noting the position of
the different-sized cap screws for joining purposes.

MD1313

Disassembling
Crankcase Half
NOTE: To aid in installing, it is recommended
that the assemblies be kept together and in order.
MD1006

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

MD1012

2. Using Crankcase Separator/Crankshaft Remover and
tapping lightly with a rubber mallet, separate the
crankcase halves. Account for two alignment pins.

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.

CC869

NOTE: To keep the shaft/gear assemblies intact
for identification, tap the shafts toward the leftside crankcase half when separating the halves.

FI660A

FI659A

FI653A

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

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).

FI650A

5. Remove the countershaft assembly (E) along with
the shift fork assembly.

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).

FI646

FI662

6. Remove the crank balancer driven gear (G) and
account for a key; then remove the crankshaft balancer shaft.

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.
MD1024

7. Using Crankcase Separator/Crankshaft Remover
with the appropriate crankshaft protector, remove the
crankshaft.

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 (0.0020.013 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.
MD1330

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.

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.

AT THIS POINT
To service crankshaft assembly, see Servicing Center
Crankcase Components sub-section.

Servicing Center
Crankcase Components
SECONDARY GEARS
NOTE: When checking and correcting secondary
gear backlash and tooth contact, the universal
joint must be secured to the front shaft or false
measurements will occur.

2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.
NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Note the following chart.
Backlash Measurement

Shim Correction

Under 0.05 mm (0.002 in.)

Decrease Shim Thickness

At 0.05-0.33 mm
(0.002-0.013 in.)

No Correction Required

Over 0.33 mm (0.013 in.)

Increase Shim Thickness

Checking Tooth Contact
NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check
tooth contact.

1. Remove the secondary driven output shaft assembly
from the left-side crankcase half.
2. Clean the secondary driven bevel gear teeth of old oil
and grease residue.
3. Apply a thin, even coat of a machinist-layout dye to
several teeth of the gear.
4. Install the secondary driven output shaft assembly.
5. Rotate the secondary driven bevel gear several revolutions in both directions.
6. Examine the tooth contact pattern in the dye and
compare the pattern to the illustrations.
71

NOTE: To correct tooth contact, steps 1 and 2
(with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted.

CAUTION
After correcting tooth contact, backlash must again be
checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures
until they are both within tolerance values.

CRANKSHAFT ASSEMBLY
ATV-0103

NOTE: The crankshaft and connecting rod is a
non-serviceable assembly. If any component is out
of specification, the assembly must be replaced.

Measuring Connecting Rod
(Small End Inside Diameter)
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and measure
it with micrometer.

ATV-0105

CC290D

2. Maximum diameter must not exceed specifications.
ATV-0104

Correcting Tooth Contact
NOTE: If tooth contact pattern is comparable to
the correct pattern illustration, no correction is
necessary.

If tooth contact pattern is comparable to an incorrect
pattern, correct tooth contact according to the following chart.
Tooth Contact

Shim Correction

Contacts at Top

Decrease Shim Thickness

Contacts at Root

Increase Shim Thickness

Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and mount
a dial indicator and base on the surface plate. Position the indicator contact point against the center of
the connecting rod small end journal.
2. Zero the indicator and push the small end of the connecting rod away from the dial indicator.
3. Maximum deflection must not exceed specifications.
Measuring Connecting Rod
(Big End Side-to-Side)
1. Push the lower end of the connecting rod to one side
of the crankshaft journal.
2. Using a feeler gauge, measure the gap between the
connecting rod and crankshaft journal.

CC289D

3. Acceptable gap range must be within specifications.
Measuring Crankshaft (Runout)

H1-006

2. Acceptable width range must be within specifications.
COUNTERSHAFT

1. Place the crankshaft on a set of V blocks.
2. Mount a dial indicator and base on the surface plate.
Position the indicator contact at point 1 of the crankshaft.

CAUTION
When disassembling the countershaft, care must be
taken to note the direction each major component (dog,
gear) faces. If a major component is installed facing the
wrong direction, transmission damage may occur and/
or the transmission will malfunction. In either case,
complete disassembly and assembly will be required.

Disassembling
1. Remove the reverse driven gear dog; then remove
the circlip securing the reverse driven gear.

H1-003A

3. Zero the indicator and rotate the crankshaft slowly.

CAUTION
Care should be taken to support the connecting rod
when rotating the crankshaft.

4. Maximum runout must not exceed specifications.
NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4.

FI663

Measuring Crankshaft (Web-toWeb)
1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other
web.

FI664

2. Remove the splined washer; then remove the reverse
driven gear along with the bearing and bushing.

FI665

FI669

3. Remove the low driven gear washer; then remove the
low driven gear along with the bearing and bushing.

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.

FI666
FI670

FI667

4. Remove the splined washer; then remove the circlip
securing the high-low sliding dog. Remove the sliding dog.

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.

FI668

FI671A

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.

FI670

2. Install the high/low shift dog (6) on the countershaft
and secure with snap-ring (7); then install the splined
washer (8).

FI665A

FI668A

FI664

3. Install the low driven bushing (10), bearing (9), and
gear (11) on the countershaft; then install splined
washer (12).

5. Install the reverse dog on the shaft; then place the
shift forks and shift shaft into position.

FI663
FI667A

FI662

NOTE: The countershaft assembly is now ready
to be installed.

MD1333

3. Apply a liberal amount of oil to the crankshaft bearing. Using a propane torch, heat the bearing until the
oil begins to smoke; then slide the crankshaft assembly into place.

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.

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.

MD1199

MD1024

5. Install the key in the crank balancer shaft; then install
the gear and aligning the timing marks, slide the gear
into place.

MD1079

2. Install and tighten the output shaft flange nut to 59 ftlb. Using a punch, peen the nut.
76

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.

FI658

6. Align the shift cam fork slots with the shift fork shaft
locating boss and with a washer on each end, install
in the crankcase.

FI653A

FI655A

FI652A

7. Place the shift forks into position on the assembled
countershaft and install into the crankshaft as an
assembly.

9. Install the input driveshaft.

FI646
FI662

10. Install the spacer (1), shaft (2), reverse idler gear, and
washer (3).

FI653
FI641A

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 Loctite #5900 or suitable substitute sealant to
the mating surfaces. Place the right-side half onto the
left-side half.
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 Cring.

FI639B

NOTE: Be sure to apply silicone to the inside
radius of all cap screw locations and the entire
surface of the internal cap screw bosses.

FI660A

FI639D

2. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed.
FI659A

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.

FI661A

Servicing Engine (700)

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.

Top-Side Components.................................................79
Removing Top-Side Components................................79
Servicing Top-Side Components.................................83
Installing Top-Side Components .................................90
Left-Side Components ................................................94
Removing Left-Side Components ...............................95
Servicing Left-Side Components.................................96
Installing Left-Side Components .................................98
Right-Side Components ............................................101
Removing Right-Side Components ...........................101
Servicing Right-Side Components ............................104
Installing Right-Side Components.............................105
Center Crankcase Components ................................108
Separating Crankcase Halves...................................108
Disassembling Crankcase Half .................................108
Servicing Center Crankcase Components ................110
Assembling Crankcase Half ......................................115
Joining Crankcase Halves.........................................117

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.
CC871

5. In a crisscross 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 pattern, tighten the 6 mm cap screws
to 10 ft-lb.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.

AT THIS POINT
After completing center crankcase components, proceed to Installing Right-Side Components, to Installing
Left-Side Components, and to Installing Top-Side Components.

AT THIS POINT
To service any one specific component, only limited disassembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to
removed from the frame for this procedure.

Removing Top-Side
Components
A. Valve Cover/Rocker Arms
B. Cylinder Head/Camshaft
NOTE: Remove the spark plug and timing inspection plug; then using a socket and ratchet, rotate the
crankshaft to top-dead-center of the compression
stroke.

1. Remove the two tappet covers.

CC001D

CD211A

NOTE: Keep the mounting hardware with the covers
for assembly purposes or thread them back into the
head to keep them separated.

5. Loosen the cap screw on the end of the tensioner;
then remove the two cap screws securing the tensioner adjuster assembly and remove the assembly.
Account for a gasket.

2. Remove the twelve cap screws securing the valve
cover to the head.
3. Remove all cap screws except the two top-side cap
screws next to the spark plug. These will keep the
alignment pins in place. Note the two rubber washers
on the remaining cap screws.

CC009D

6. Using an awl, rotate the C-ring in its groove until it is
out of the cylinder head; then remove the C-ring.
NOTE: Care should be taken not to drop the C-ring
down into the crankcase.
H1-013A

4. Remove the valve cover. Account for and note the
orientation of the cylinder head plug. Note the location of the two alignment pins.

CC012D

7. Bend the washer tabs down and remove the two cap
screws securing the sprocket to the camshaft; then
drop the sprocket off the camshaft.
CD206

CC017D

CC013D

8. While holding the chain, slide the sprocket and camshaft
out of the cylinder head.
NOTE: Loop the chain over the cylinder and secure
it to keep it from falling into the crankcase.

CC018D

11. Remove the four cylinder head bolts.
NOTE: Account for rubber O-rings.

FI620

9. Remove the cap screw securing the chain tensioner
(account for a washer); then remove the tensioner.

H1-016A

12. Remove the cylinder head from the cylinder, remove
the gasket, and account for two alignment pins; then
remove the cam chain guide.
FI617

10. Remove the five nuts securing the cylinder head to the
cylinder.

CC020D

AT THIS POINT
To service valves and cylinder head, see Servicing TopSide Components sub-section.

AT THIS POINT
To inspect cam chain guide, see Servicing Top-Side
Components sub-section.

CC025D

CC022D

C. Cylinder
D. Piston
NOTE: Steps 1-12 in the preceding sub-section
must precede this procedure.
CC026D

13. Loosen the clamp securing the coolant hose to the union;
then detach the hose.
14. Remove the two nuts securing the cylinder to the crankcase.

AT THIS POINT
To service cylinder, see Servicing Top-Side Components sub-section.

CAUTION
When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston.

16. Using an awl, remove one piston-pin circlip.

CC023D

15. Lift the cylinder off the crankcase taking care not to
allow the piston to drop against the crankcase. Account
for the gasket and two alignment pins.
CC032D

17. Using the Piston Pin Puller, remove the piston pin.
Account for the opposite-side circlip. Remove the
piston.
NOTE: It is advisable to remove the opposite-side
circlip prior to using the puller.

CC024D

1. Wash the valve cover in parts-cleaning solvent.
2. Place the valve cover on the Surface Plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the valve cover in a figure eight
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assembly by continuing to move the valve cover in a figure
eight motion until a uniform bright metallic finish is
attained.

CAUTION
CC033D

NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install the Connecting Rod Holder.

Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always
check camshaft clearance when resurfacing the valve
cover.

CAUTION
Do not allow the connecting rod to go down inside the
crankcase. If the rod is down inside the crankcase and
the crankshaft is rotated, severe damage will result.

NOTE: If the existing rings will not be replaced with
new rings, note the location of each ring for proper
installation. When replacing with new rings, replace
as a complete set only. If the piston rings must be
removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the
ring out of the ring-groove.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove.

AT THIS POINT
To service piston, see Servicing Top-Side Components
sub-section.

AT THIS POINT
To service center crankcase components only, proceed
to Removing Left-Side Components.

Servicing Top-Side
Components

CC130D

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

Removing Valves
NOTE: Index all valves, springs, and cotters to their
original position when removing. When installing, all
valve components should be installed in their original position.

1. Using a valve spring compressor, compress the valve
springs and remove the valve cotters. Account for an
upper spring retainer.

VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it must
be replaced.

Cleaning/Inspecting Valve Cover
NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced.

CC132D

2. Remove the valve seal and the lower remaining
spring seat. Discard the valve seal.

2. Acceptable width ranges must not exceed specifications.
Measuring Valve Face Radial Runout

1. Mount a dial indicator on the surface plate; then
place the valve stem on a set of V blocks.
2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator.

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.
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.
ATV-1082

2. Maximum runout must not exceed specifications.
Measuring Valve Stem Outside
Diameter
1. Using a micrometer, measure the valve stem outside
diameter.
2. Acceptable diameter range must be within specifications.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the valve face.
CC131D

3. Push the valve from side to side; then from top to
bottom.
4. Maximum “wobble” deflection must not exceed
specifications.
Measuring Valve Guide
(Inside Diameter)
1. Insert a snap gauge 1/2 way down into each valve
guide bore; then remove the gauge and measure it
with a micrometer.
ATV-1004

2. Acceptable inside diameter range must be within
specifications.

3. If a valve guide is out of tolerance, it must be
replaced.
Servicing Valves/Valve Guides/Valve
Seats
If valves, valve guides, or valve seats require servicing or
replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing.

CAUTION
If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt
to grind the valves or severe engine damage may occur.

Measuring Rocker Arm
(Inside Diameter)
1. Using a dial calipers, measure the inside diameter of
the rocker arm.

ATV-1011A

4. Place a spring retainer over the valve springs; then
using the valve spring compressor, compress the
valve springs and install the valve cotters.

2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter of
the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
Installing Valves

CC132D

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.

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 dome of the piston.
2. Inspect the piston for cracks in the piston pin, dome,
and skirt areas.
3. Inspect the piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and
water or honing oil.
CC144D

NOTE: If scuffing or seizure marks are too deep to
correct with the sandpaper, replace the piston.

3. Install the valve springs with the painted end of the
spring facing away from the cylinder head.

4. Inspect the perimeter of each piston for signs of
excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.

2. Insert each valve into its original location.

NOTE: If the paint is not visible, install the ends of
the springs with the closest wound coils toward the
head.

Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.

Measuring Piston Pin (Outside
Diameter) and Piston-Pin Bore
1. Measure the piston pin outside diameter at each end
and in the center. If measurement is not within specifications, the piston pin must be replaced.

CC400D

2. Remove each ring by working it toward the dome of
the piston while rotating it out of the groove.
NOTE: If the existing rings will not be replaced with
new ones, note the location of each ring for proper
installation. When installing new rings, install as a
complete set only.

Cleaning/Inspecting Piston Rings
1. Take an old piston ring and snap it into two pieces;
then grind the end of the old ring to a 45° angle and
to a sharp edge.

ATV-1070

2. Insert an inside dial indicator into the piston-pin
bore. The diameter must not exceed specifications.
Take two measurements to ensure accuracy.

2. Using the sharpened ring as a tool, clean carbon from
the ring-grooves. Be sure to position the ring with its
tapered side up.

CAUTION
Improper cleaning of the ring-grooves by the use of the
wrong type of ring-groove cleaner will result in severe
damage to the piston.

Measuring Piston-Ring End Gap
(Installed)

ATV-1069

1. Place each compression ring in the wear portion of
the cylinder. Use the piston to position each ring
squarely in the cylinder.
2. Using a feeler gauge, measure each piston-ring end
gap. Acceptable ring end gap must not exceed specifications.

Measuring Piston Skirt/Cylinder
Clearance
1. Measure the cylinder front to back in six places.

CC127D

CC280D

2. Measure the corresponding piston diameter at the
recommended point above the piston skirt at a right
angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference
(clearance) must not exceed specifications.

Installing Piston Rings
1. Install ring expander (4) in the bottom groove of the
piston; then install the thin oil rings (3) over the
expander making sure the expander ends do not
overlap. Stagger the end gaps of the upper and lower
thin oil rings according to the illustration.

CYLINDER/CYLINDER HEAD
ASSEMBLY
NOTE: If the cylinder/cylinder head cannot be trued,
they must be replaced as an assembly.

Cleaning/Inspecting Cylinder Head

CAUTION
The cylinder head studs must be removed for this procedure.

ATV-1085B

NOTE: Note the direction of the exhaust side of the
piston (5) for correct ring end gap orientation.

2. The ring with the orientation mark (MTOP or TOP)
should be installed in the second (middle) groove
and the ring with the orientation mark (M or O)
should be installed in the first (top) groove.

3. Place the cylinder head on the Surface Plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder head in a figure eight
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic
finish is attained.

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

ATV-1024A

CC128D

3. Maximum distortion must not exceed specifications.

CAUTION
Incorrect installation of the piston rings will result in
engine damage.

Inspecting Cylinder
1. Using a slide gauge and a dial indicator or a snap
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a total
of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness)
must not exceed specifications.

CC141D

Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning solvent.
2. Inspect the cylinder for pitting, scoring, scuffing,
warpage, and corrosion. If marks are found, repair
the surface using a cylinder hone (see Inspecting
Cylinder in this sub-section).
3. Place the cylinder on the surface plate covered with
#400 grit wet-or-dry sandpaper. Using light pressure,
move the cylinder in a figure eight motion. Inspect
the sealing surface for any indication of high spots.
A high spot can be noted by a bright metallic finish.
Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion
until a uniform bright metallic finish is attained.

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

CC127D

2. Wash the cylinder in parts-cleaning solvent.
3. Inspect the cylinder for pitting, scoring, scuffing, and
corrosion. If marks are found, repair the surface
using a #320 grit ball hone.
NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30
strokes per minute. If honing oil is not available, use
a lightweight petroleum-based oil. Thoroughly clean
cylinder after honing using soap and hot water. Dry
with compressed air; then immediately apply oil to
the cylinder bore. If the bore is severely damaged or
gouged, replace the cylinder.

CC129D

Inspecting Cam Chain Guide
CC390D

1. Inspect cam chain guide for cuts, tears, breaks, or
chips.
2. If the chain guide is damaged, it must be replaced.

4. If any measurement exceeds the limit, replace the
cylinder and piston.
Measuring Camshaft Runout
NOTE: If the camshaft is out of tolerance, it must be
replaced.

1. Place the camshaft on a set of V blocks; then position
the dial indicator contact point against the shaft and
zero the indicator.
88

4. Remove the cap screws securing the valve cover to
the cylinder; then remove the valve cover and camshaft.

CC283D

2. Rotate the camshaft and note runout; maximum runout must not exceed specifications.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.

CC003D

5. Match the width of the plasti-gauge with the chart
found on the plasti-gauge packaging to determine
camshaft to cylinder head and valve cover clearance.

ATV1013A

2. The lobe heights must be greater than minimum
specifications.
Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be replaced.
Measuring Camshaft to Cylinder
Head Clearance

CC145D

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

1. Remove the adjuster screws and jam nuts.

CC287D

CC005D

NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.
89

Inspecting Camshaft Spring/Drive
Pin
1. Inspect the spring and drive pin for damage.

2. Place the two alignment pins into position. Place the
cylinder gasket into position; then place a piston
holder (or suitable substitute) beneath the piston skirt
and square the piston in respect to the crankcase.

CF083

CF061A

CAUTION
The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur.

CF060A

2. If damaged, the camshaft must be replaced.

Installing Top-Side
Components
A. Piston
B. Cylinder
1. Install the piston on the connecting rod making sure
the circlip on each side is fully seated in the piston.
NOTE: The piston should be installed so the arrow
points toward the exhaust.

CC024D

4. Loosely install the two nuts which secure the cylinder to the crankcase.
NOTE: The two cylinder-to-crankcase nuts will be
tightened in step 11.

CC032D
CC023D

5. Install the coolant hose onto the crankcase union and
tighten the clamp.
C. Cylinder Head
D. Valve Cover
NOTE: Steps 1-5 in the preceding sub-section must
precede this procedure.

6. Place the chain guide into the cylinder.

CAUTION
Care should be taken that the bottom of the chain guide
is secured in the crankcase boss.
CF289A

8. Install the four cylinder head cap screws and washers. Tighten only until snug.

CF058A

7. Place a new head gasket into position on the cylinder. Place the alignment pins and four O-rings into
position; then place the head assembly into position
on the cylinder.

CC272D

9. Loosely install the five cylinder head nuts.
10. Using a crisscross pattern, tighten the four cap screws
(from step 8) initially to 20 ft-lb; then in 10 ft-lb increments, tighten to a final torque of 40 ft-lb.
11. Tighten the 8 mm nuts from step 9 to 21 ft-lb and the 6
mm nuts to 8.5 ft-lb; then tighten the two cylinder-tocrankcase nuts (from step 4) securely.
12. With the timing inspection plug removed and the chain
held tight, rotate the crankshaft until the piston is at topdead-center.
13. Install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer.

CC020D

CD461
CF057A

NOTE: At this point, oil the camshaft journals, cam
lobes, and the three seating surfaces on the cylinder.

14. With the alignment pin installed in the camshaft, loosely
place the cam sprocket (with the recessed side facing the
cam shaft lobes) onto the camshaft. At this point, do not
“seat” the sprocket onto the shaft.

A. Piston still at top-dead-center.
B. Camshaft lobes directed down (toward the piston).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
D. Recessed side of the sprocket directed toward the
cam lobes.
E. Camshaft alignment pin and sprocket alignment
hole (smallest) are aligned.

CAUTION
If any of the above factors are not as stated, go back to
step 12 and carefully proceed.
732-307B

17. Place the tab-washer onto the sprocket making sure it
covers the pin in the alignment hole.

15. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly
through the chain and towards its seating position;
then loop the chain over the sprocket.
NOTE: Note the position of the alignment marks on
the end of the camshaft. They must be parallel with
the valve cover mating surface. If rotating the camshaft 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.

ATV1027

CAUTION
Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the
alignment pin falls out, severe engine damage will
result.

18. Install the first cap screw (threads coated with red
Loctite #271) securing the sprocket and tab-washer
to the camshaft. Tighten only until snug.
CD463

16. Seat the cam sprocket onto the camshaft making sure
the alignment pin in the camshaft aligns with the
smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring
the following.

CD464

19. Rotate the crankshaft until the second cap screw
securing the sprocket to the camshaft can be
installed; then install the cap screw (threads coated
with red Loctite #271) and tighten to 10 ft-lb. Bend
the tab to secure the cap screw.
CF013A

CD465

CD468

20. Rotate the crankshaft until the first cap screw (from
step 18) can be accessed; then tighten to 10 ft-lb.
Bend the tab to secure the cap screw.

23. Remove the cap screw from the end of the chain tensioner; then using a flat-blade screwdriver, rotate the
adjuster screw inside the tensioner clockwise until
the screw bottoms.

CD466

21. Place the C-ring into position in its groove in the cylinder head.

CD501

NOTE: The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise. The
adjuster shaft tension will be released in step 25.

24. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the
two cap screws.

CC012D

22. Install the cylinder head plug in the cylinder head
with the open end facing downward and toward the
inside.

CAUTION
The open end of the plug must be positioned downward.

CD469

25. Using a flat-blade screwdriver, rotate the adjuster
screw inside the tensioner counterclockwise until all
tension is released; then install the cap screw into the
end of the chain tensioner.

NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.

29. Install the four top side cap screws with rubber washers; then install the remaining cap screws. Tighten
only until snug.

CD470

CC003D

30. In a crisscross pattern starting from the center and
working outward, tighten the cap screws (from step
29) to 8.5 ft-lb.
31. Adjust valve/tappet clearance (see Periodic Maintenance).
CD471

26. Loosen the four adjuster screw jam nuts; then loosen
the four adjuster screws on the rocker arms in the
valve cover.

32. Place the two tappet covers into position making sure
the proper cap screws are with the proper cover.
Tighten to 8.5 ft lb.

CC001D
CC005D

27. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder head and valve cover.

33. If removed, install the spark plug. Tighten securely.

Left-Side Components
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment.

AT THIS POINT
To service any one specific component, only limited disassembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
CC275D

28. Place the valve cover into position.
94

NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.

7. Using an appropriate side case puller, remove the
side cover. Account for a gasket and two alignment
pins.

Removing Left-Side
Components
A.
B.
C.
D.

6. Remove the cap screws securing the left-side cover
to the crankcase noting the location of the differentsized cap screws for installing purposes.

8. Remove the nut securing the magneto rotor to the
crankshaft; then install the magneto rotor puller
adapter.

Outer Magneto Cover
Water Pump
Cover
Rotor/Flywheel

NOTE: The puller has left-hand threads.

1. Remove the four cap screws securing the outer magneto cover to the left-side cover; then remove the
outer magneto cover.

9. Using Magneto Rotor Remover Set and the appropriate crankshaft protector, remove the rotor/flywheel
assembly from the crankshaft. Account for the key;
then remove the starter clutch gear assembly and
washer.

2. Remove the flange nut securing the bushing to the
crankshaft; then remove the bushing. Account for the
O-ring inside the spacer.
3. Remove the cap screws securing the speed sensor
housing to the crankcase and remove the housing
assembly; then remove the snap ring securing the
speed sensor trigger to the shaft and remove the trigger. Account for the gasket.
NOTE: It may be necessary to use a small two-jaw
puller to remove the trigger.

PR441

CD920

CD939A

GZ254

4. Loosen the clamps securing the coolant hose to the
water pump; then remove the crossover tube from
the cylinder head. Account for an O-ring.
5. Remove the two cap screws securing the water pump
to the engine; then remove the water pump.

CD940A

10. Remove the two starter gears from the crankcase noting the direction of the beveled side of the gears for
installing purposes; then remove the two starter gear
shafts.
95

NOTE: There is an oil passage beneath the driven
gear/drive gear assembly. This passage should be
plugged prior to removing the driven gear and drive
gear. Failure to do so could result in the loss of an
alignment pin into the crankcase.

13. Remove the shift shaft noting the timing marks for
assembling purposes. Account for two washers.

CD136

PR430A

14. Remove the gear shift cam plate and account for a
washer; then remove the cam stopper and cam stopper spring. Account for two washers.
CD140

11. Remove the snap ring securing the water pump drive
gear; then remove the gear noting the direction of the
sides of the gear for installing purposes. Account for the
drive gear alignment pin.

PR434A

Servicing Left-Side
Components
CD944

12. Remove the snap ring securing the water pump driven
gear; then remove the gear noting the direction of the
sides of the gear for installing purposes. Account for the
driven gear alignment pin.

INSPECTING STARTER CLUTCH/
GEAR
1. Place the starter clutch gear onto the rotor/flywheel
and attempt to rotate the starter clutch gear clockwise. 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.

CD952A

FI569

FI576A

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.

FI578

FI572

REPLACING STARTER CLUTCH
ASSEMBLY
1. Remove the cap screws securing the starter clutch
assembly to the flywheel; then remove from the flywheel.

FI583
FI570

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 COIL/
MAGNETO COVER ASSEMBLY
1. Inspect the stator coil for burned or discolored wiring, broken or missing hold-down clips, or loose cap
screws.
2. Inspect the bearings in the magneto housing for discoloration, roughness when rotated, and secure fit in
bearing bores.
REPLACING STATOR COIL/
CRANKSHAFT POSITION SENSOR
1. Remove the three cap screws securing the stator coil,
two cap screws securing the crankshaft position sensor, and one cap screw from the harness hold-down.

FI595A

Installing Left-Side
Components
NOTE: Plug the oil passage in the crankcase housing prior to installing the drive gear/driven gear
assembly to prevent loss of an alignment pin.

1. Install the water pump driven gear alignment pin and
the driven gear (with the beveled side of the gear facing outward as noted in removing); then secure with
the snap ring.

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.

CD950A

FI590

3. Install the new stator coil assembly and secure with
three new “patch-lock” cap screws. Tighten to 15 ftlb.
4. Place the stator wire harness hold-down into position; 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.

CD952A

CD949

CD139

NOTE: The sharp side of the snap ring should be
facing outward.

2. Install the water pump drive gear drive pin and the
drive gear (with the flat side of the gear facing outward as noted in removing); then secure with the
snap ring.

PR447A

4. In order on the crankshaft, install a washer, ring gear,
key, and the magneto rotor. Secure with the nut.
Tighten to 107 ft-lb.

CD946A

CD948A

CD944

NOTE: The sharp side of the snap ring should be
facing outward.
NOTE: Once the gears are secured, remove the oil
passage plug from the crankcase.

3. Install the two starter gear shafts; then install the two
starter gears (with the beveled side of the intermediate gear facing inward as noted in removing).
CD940B

5. Install the thrust washer and shift cam plate onto the
shift cam shaft; then coat the cap screw threads with
red Loctite #271 and tighten to 8 ft-lb.
99

PR433A

CD954A

CD934

CD927A

6. Install the shift cam stopper, spring, and two washers
(thick washer closest to the nut); then coat the
threads on the mounting stud with red Loctite #271
and install the nut. Tighten to 8 ft-lb.

8. Lubricate the magneto cover gasket with fresh
engine oil; then place it into position on the two
alignment pins. Make sure the outer shift shaft
washer is in place.

PR434A

NOTE: Rotate the shift cam plate to ensure it ratchets with no binding.

7. Install the shift shaft with two washers making sure
to align the timing mark on the shift shaft with the
mark on the shift cam plate.

PR431A

9. Install the magneto cover and secure with the cap
screws. Tighten only until snug.
10. Place the bushing into position on the crankshaft
making sure a new, lubricated O-ring is inside the
bushing. Tighten the flange nut to 25 ft-lb.
11. Using a crisscross pattern, tighten the cap screws
(from step 9) to 8 ft-lb.
12. Clean the countershaft and trigger splines thoroughly
and install the inner snap ring onto the shaft; then
apply green Loctite #620 to the trigger and countershaft splines and install the trigger. Secure with a flat
washer and outer snap ring.

100

Right-Side Components
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment.

AT THIS POINT
GZ253

To service any one specific component, only limited disassembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.

Removing Right-Side
Components

GZ254

13. Using a new gasket, install the speed sensor housing
onto the crankcase and secure with two cap screws.
Tighten to 8 ft-lb.

A.
B.
C.
D.

V-Belt Cover
Driven Pulley
Clutch Cover
Oil Pump

1. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover. Account for two alignment pins.

CD069

14. Place the water pump into position and secure with
two cap screws. Tighten to 8 ft-lb.
NOTE: Ensure the slotted water pump shaft is
aligned with the groove in the counter balancer shaft.

15. Install the crossover tube on the water pump and cylinder head making sure the O-ring is properly positioned.

CD079

2. Remove the nut and washer securing the movable drive
face; then remove the face. Account for a spacer.

16. Place the outer magneto cover into position on the
left-side cover; then tighten four cap screws to 6 ftlb.

101

CD963

CD973A

CAUTION
Care must be taken when removing the cover so the
cover gasket is not damaged.

CD966A

3. Remove the V-belt.
4. Remove the nut securing the fixed driven assembly; then
remove the assembly.

CD974A

NOTE: For steps 7-12, refer to illustration CC829B.
NOTE: To aid in installing, it is recommended that
the assemblies are kept together and IN ORDER.

PR388

5. Remove the fixed drive face.
6. Remove the cap screws securing the clutch cover. Note
the location of the different-lengthed cap screws for
installing purposes. Using a rubber mallet, carefully
remove the cover. Account for two alignment pins.

KEY
A. Oil Pump Driven Gear
B. Oil Pump Drive Gear
C. Clutch Shoe Assembly

D. One-Way Clutch
E. Final Drive Carrier Bearing
Housing
CC829B

7. Remove the one-way clutch (D) from the clutch
housing. Note the location of the green alignment dot
(or the word OUTSIDE) for installing purposes.
8. Using a hydraulic press, remove the clutch housing
assembly from the clutch cover. Account for the left
fixed drive spacer and an O-ring inside the fixed
drive spacer.

102

10. Remove the cap screw securing the oil pump drive
gear (B). Account for a cap screw, washer, pin, and
spacer.

CF085

CC606

CC596

NOTE: Account for and inspect the clutch housing
seal.
CD987

CF088A

9. Remove the nut (left-hand threads) securing the clutch
shoe assembly (C).

CD993

11. Using an impact wrench, remove the cap screws
securing the final drive carrier bearing housing (E);
then remove the housing and account for two alignment pins.

PR410A

103

CD999

12. Remove the snap ring securing the oil pump driven
gear (A); then remove the gear noting the direction
of the sides of the gear for installing purposes.
Account for a pin and a washer.

CD988

Servicing Right-Side
Components
INSPECTING CENTRIFUGAL CLUTCH
SHOE
1. Inspect the clutch shoes for uneven wear, chips,
cracks, or discoloration. If any shoe is damaged,
replace the complete set.
2. Inspect the clutch shoes for wear or damage. If any
shoe is worn to the bottom of the groove, replace the
clutch assembly.

CD984

ATV1014
CD895A

13. Using an impact driver, remove the three torx-head
screws securing the oil pump; then remove the
pump.

INSPECTING CLUTCH HOUSING
1. Inspect the clutch housing for burns, grooving,
cracks, or uneven wear.
2. If the housing is damaged in any way, the housing
must be replaced.
INSPECTING PRIMARY
ONE-WAY DRIVE
1. Insert the drive into the clutch housing.
2. Rotate the inner race by hand and verify the inner
race rotates only one direction.
3. If the inner race is locked in place or rotates both
directions, the drive assembly must be replaced.

104

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.

CD988

CC446D

3. Install the oil pump drive gear spacer onto the crank
balancer shaft. Grease the pin and insert it into the
shaft; then install the drive gear making sure the
raised side of the gear is facing toward the inside.
Secure the gear with the cap screw (threads coated
with red Loctite #271) and the washer. Tighten the
cap screw to 63 ft-lb.

DRIVEN PULLEY ASSEMBLY
NOTE: The driven pulley is a non-serviceable component. If the pulley faces, cam ramps, or sheave
bushing are worn or loose, the pulley must be
replaced as an assembly. Do not disassemble the
driven pulley.

Installing Right-Side
Components
CD992

1. Install the secondary shaft bearing housing making
sure the two alignment pins are properly positioned.
Tighten the new “patch-lock” cap screws to 28 ft-lb.

CD991

CD999

2. Install the oil pump onto the engine; then tighten the
screws (coated with red Loctite #271) to 8 ft-lb.

4. Grease the driven gear pin and insert the oil pump
into the case. Tighten the oil pump screws to 8 ft-lb.
Install the washer and pin; then install the driven
gear noting the direction on the sides of the gear
from removing). Secure with a snap ring.

105

CD985A

PR399A

CAUTION
When installed correctly, the green alignment dot (or the
word OUTSIDE) on the one-way clutch is visible.

8. Lightly grease the clutch housing seal; then insert the
left fixed-drive spacer.

CD984

NOTE: When installed correctly, the sides of the
drive and driven gears will be flush with each other.

5. Install the clutch shoe assembly and secure with the
flange nut (threads coated with red Loctite #271).
Tighten to 221 ft-lb.

CF088A

PR410A

CF085A

6. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the
gasket onto the crankcase.

9. Apply grease to the outer edges of the clutch housing; then from inside the clutch cover, install the
clutch housing into the cover using a rubber mallet.

7. Install the one-way clutch onto the clutch shoe
assembly.

10. Place the clutch cover/housing assembly into position on the crankcase; then secure with the cap
screws making sure the different-lengthed cap
screws are in their proper location. Tighten to 8 ft-lb.

106

14. Place the V-belt into position on the driven pulley
and over the front shaft.

H1-023

11. Place the driven pulley assembly into position and
secure with the nut. Tighten to 162 ft-lb.
PR389

NOTE: The arrows on the V-belt should point in the
direction of rotation.

15. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the driveshaft.
Using an appropriate spanner wrench, secure the
drive face with a nut and (threads coated with red
Loctite #271). Tighten the nut to 165 ft-lb.

CAUTION
Make sure the splines extend beyond the drive face or a
false torque reading and spline damage may occur.
CF262

12. Slide the fixed drive face onto the clutch shaft.
13. Spread the faces of the driven pulley by threading a cap
screw into one of the bosses of the driven fixed face;
then tighten the cap screw until the V-belt drops into the
driven pulley 1/2 to 3/4 inch.

FI428A

NOTE: At this point, the cap screw can be removed
from between the driven pulley faces.

CF270A

16. With the vehicle in neutral, rotate the V-belt and
clutches counterclockwise until the V-belt is flush
with the top of the driven pulley.
17. Place the V-belt cover gasket into position; then
install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their
proper location. Tighten the cap screws to 8 ft-lb.

H1-020A

107

Disassembling Crankcase
Half
NOTE: For steps 1-7, refer to illustration PR787A.
NOTE: To aid in installing, it is recommended that
the assemblies are kept together and IN ORDER.

CD083

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

KEY
A. Secondary Driven Shaft
Assembly
B. Crank Balancer Assembly
C. Crankshaft
D. Countershaft Assembly

E.
F.
G.
H.

Driveshaft
Reverse Idler Gear Assembly
Gear Shift Shaft
Shift Shaft with 2 Forks
PR787A

1. Remove the secondary driven shaft assembly (A)
noting the location of the bearing locating pins.
Account for the bearing C-ring.

1. Remove the right-side cap screws securing the crankcase
halves. Note the location of the different-lengthed cap
screws.
2. Remove the left-side cap screws securing the crankcase
halves. Note the location of the different-lengthed cap
screws.
3. Using the Crankcase Separator/Crankshaft Remover and
tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins.
NOTE: To keep the shaft/gear assemblies intact for
identification, tap the shafts toward the left-side crankcase half when separating the halves.

PR786

108

PR787B

2. Remove the reverse idler gear assembly (F). Account
for all washers, shaft, bushing, and the gear.

CC668

3. Remove the shift shaft (H); then remove the two
forks taking note of the direction of the tabs on the
forks for assembling purposes.
4. Remove the gear shift shaft (G) noting the location
of the two holes on the end of the shaft. Account for
a spacer and a washer.

CD826

8. Remove the crank balancer.
NOTE: There is a flat spot on the crank balancer
bearing flange to allow clearance past the crankshaft.

DE677A

5. Remove the countershaft assembly (D). Account for
a washer on each end of the countershaft.

CD832B

9. Remove the snap ring securing the water pump
driven gear shaft.
CC674

NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing
Center Crankcase Components sub-section.

6. Using a rubber mallet, tap on the crankcase to
remove the driveshaft.

10. Using a hydraulic press, remove the crankshaft
assembly.
NOTE: Use a protective end cap to prevent damage
to the crankshaft threads.

11. Remove the cap screws securing the oil strainer cap;
then remove the cap.
12. Remove the two cap screws securing the oil strainer;
then remove the strainer.
NOTE: Thoroughly clean any sealant from the oil
strainer cap.

CC675

7. Note the timing marks on the crank balancer assembly (B) gear and crankshaft (C) gear for assembling
purposes; then slide the crank balancer gear off the
crank balancer. Account for the key in the keyway.

PR406

109

CAUTION
Unless the secondary drive gear, bevel gear, or bearings require service, do not remove the secondary drive
assembly from the case. If removed, bevel gear backlash will have to be adjusted requiring re-shimming of
the drive bevel gear shaft.

13. To remove the secondary drive/bevel gear, remove
the secondary drive bearing housing; then remove
the nut securing the drive/bevel gear shaft in the
bearing and using a plastic mallet, drive the shaft out
of the bearing. Account for shim/shims.
NOTE: Shims should be measured and kept for a
starting point in adjusting backlash.

Servicing Center
Crankcase Components

MT011B

3. If installing the existing shaft, start with the shims
removed during disassembly or if installing a new
shaft, start with approximately 1.0 mm shims at point
(D); then install the output drive shaft bearing (E)
making sure the locating pin is directed toward the
center of the shaft.

SECONDARY OUTPUT DRIVE GEARS
Initial Set-Up
NOTE: If the secondary output driven shaft is
replaced or disassembled, the initial set-up must be
performed to establish correct gear tooth contact. If
only the secondary output drive shaft or secondary
output driven gear is replaced, proceed to Correcting
Backlash in this sub-section.

1. Install a new bearing (A) onto the secondary driven
shaft (B) making sure the bearing locating groove is
directed away from the driven gear splines.

MT012

MT011A

4. Install a new seal (F), output yoke (G), and nut (H)
and tighten to 74 ft-lb.

MT008A

2. Using a suitable press, install the driven gear (C) on
the shaft until the gear firmly seats on the shoulder of
the shaft.

110

MT008B

NOTE: Do not use a new lock nut at this time as this
procedure may have to be repeated.

5. Place the assembled shaft into the left crankshaft
case; then lightly coat the gear teeth with machinist’s
lay-out dye. Rotate the shafts through several rotations in both directions. Gear contact should extend
from the root to the top of the gear teeth.

MT005A

5. Acceptable backlash range is 0.127-0.381 mm
(0.005-0.015 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.
Backlash Measurement

MT016A

6. To adjust tooth contact, use the following chart to
correctly shim the driven shaft.
Tooth Contact

Shim Correction

Contact at Top

Increase Shim Thickness

Contact at Root

Decrease Shim Thickness

7. After correct tooth contact is established, proceed to
Checking Backlash in this sub-section.
Checking Backlash
1. If removed, install the secondary drive/bevel gear
shaft into the crankcase; then tighten the nut to 59 ftlb.
2. Install the secondary drive bearing support; then
install the secondary driven output shaft into the
crankcase.

Shim Correction

Under 0.127 mm (0.005 in.)

Decrease Shim Thickness

At 0.127-0.381 mm (0.005-0.015 in.)

No Correction Required

Over 0.381 mm (0.015 in.)

Increase Shim Thickness

After backlash and tooth contact are within specifications, apply red Loctite #271 to the driveshaft threads and
driven output shaft threads; then using new nuts, tighten
the output shaft nut to 59 ft-lb and the output yoke nut to
74 ft-lb.
CRANKSHAFT ASSEMBLY
NOTE: The crankshaft and connecting rod is a nonserviceable assembly. If any component is out of
specification, the assembly must be replaced.

Measuring Connecting Rod
(Small End Inside Diameter)
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and measure
it with micrometer.

3. Mount the dial indicator so the tip is contacting a
tooth on the secondary drive bevel gear.
4. While rocking the drive bevel gear back and forth,
note the maximum backlash reading on the gauge.

111

CC290D

2. Maximum diameter must not exceed specifications.
Measuring Connecting Rod
(Small End Deflection)

H1-003

3. Zero the indicator and rotate the crankshaft slowly.

CAUTION

1. Place the crankshaft on a set of V blocks and mount a
dial indicator and base on the surface plate. Position
the indicator contact point against the center of the
connecting rod small end journal.
2. Zero the indicator and push the small end of the connecting rod away from the dial indicator.
3. Maximum deflection must not exceed specifications.
Measuring Connecting Rod
(Big End Side-to-Side)
1. Push the lower end of the connecting rod to one side
of the crankshaft journal.

Care should be taken to support the connecting rod
when rotating the crankshaft.

4. Maximum runout must not exceed specifications.
NOTE: Proceed to check runout on the other end of
the crankshaft by positioning the indicator contact at
point 2 and following steps 3-4.

Measuring Crankshaft (Web-toWeb)
1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other
web.

2. Using a feeler gauge, measure the gap between the
connecting rod and crankshaft journal.

H1-005

2. Acceptable width range must not exceed specifications.
CC289D

3. Acceptable gap range must not exceed 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.

112

COUNTERSHAFT

GZ312

3. Remove the reverse driven gear dog.
GZ281A

Disassembling
1. Remove the shift forks noting the positions for
assembling; then remove the high driven gear outer
washer, high driven gear, high driven gear bearing,
high driven gear bushing, and high driven gear inner
washer.

4. Remove the snap ring securing the reverse driven
gear and washer; then remove the washer and gear.

GZ283A

GZ314

2. Remove the drive gear; then remove the snap ring
securing the reverse driven gear dog and bushing to
the countershaft.

5. Remove the reverse driven washer; then remove the
low driven gear locking washer.

GZ313A

GZ320
GZ296

113

GZ319

GZ318A

GZ317A

GZ318

6. Remove the low driven gear. Account for a bearing,
bushing, and thrust washer.

2. Install the low driven gear locking washer; then
install the inner reverse driven gear washer.

GZ316

GZ319B

Assembling
1. From the drive gear end, install a thrust washer,
bushing, and bearing; then install the low driven gear
and washer.

GZ320B

3. Install the reverse driven bushing and bearing; then
install the reverse driven gear.

114

GZ286A

GZ313A

GZ287

GZ312

4. Install the outer reverse driven washer; then secure
the reverse driven gear assembly with a snap ring.

6. From the opposite end of the countershaft, install the
high/low driven gear dog (A), thrust washer (B),
bushing (C), bearing (D), high/low driven gear (E),
and spacer washer (F).

GZ288A
GZ283B

7. Install the two drive gear washers and the shift forks.
The countershaft is now ready for installation.
NOTE: When installing the countershaft assembly,
account for the washer on each end of the shaft.

Assembling Crankcase
Half
GZ314

5. Install the reverse driven gear dog onto the countershaft and secure with a snap ring.

1. Install the secondary drive gear assembly into the
crankcase.

115

MT014

2. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the
crankshaft assembly into place.

CD832B

NOTE: It will be necessary to rotate the crank balancer until the counterweight is facing away from the
crankshaft; then rotate the crankshaft clockwise into
the journal area to allow the crank balancer to be fully
seated.

4. Place the key into the crank balancer keyway; then
install the crank balancer gear making sure the alignment dots on the crank balancer gear and the crankshaft gear align.

CC688

CD826A

5. Install the driveshaft.

CC689

NOTE: If heating the bearing is not possible, the
crankshaft can be installed using a crankshaft installing tool.

3. Install the crank balancer.
CC675

6. Place a washer on each end of the countershaft
assembly; then install the assembly.

116

CC674

CC668

7. Place a washer on the end of the gear shift shaft; then
install the shaft assembly making sure the two holes
on the end of the shaft are positioned vertically.
Install the spacer on the shift shaft.

10. Install the front and rear secondary driven shaft
assemblies into the left side of the crankcase making
sure the bearing locating pins are toward the top of
the crankcase and the bearing C-ring is fully seated
in the crankcase.

DE677A

8. Insert the two shift forks into the sliding dogs noting
the direction of the tabs from disassembling; then
install the shift fork shaft.
NOTE: Make sure the shift fork tabs face upward
and that they are properly seated into the shift cams.

PR787B

11. Place the oil strainer into position; then secure with
the two screws.
12. Place the oil strainer cap into position making sure
silicone sealant is applied; then secure the cap with
cap screws. Tighten to 10 ft-lb.

Joining Crankcase Halves
1. Apply High-Temp Sealant to the left-side mating
surface smoothing out any build-up or bumps.
2. Lightly oil all bearings and grease all shafts in the
right-side crankcase.
3. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed.
CC669

9. Install the reverse idler gear assembly noting the
positioning of the two washers, gear, bushing, and
shaft.

4. From the right side, install the 8 mm cap screws;
then tighten only until snug.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.

5. From the left side, install the remaining 8 mm cap
screws (two inside the case); then tighten only until
snug.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.
117

6. From the left side, install the case half 6 mm cap
screws; then tighten only until snug.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.

7. From the right side, install the 6 mm cap screws;
then tighten only until snug.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.

8. In a crisscross/case-to-case pattern, tighten the 8 mm
cap screws (from steps 4-5) until the halves are correctly joined; then tighten to 20 ft-lb.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.

9. In a crisscross/case-to-case pattern, tighten the 6 mm
cap screws (from steps 6-7) to 8 ft-lb.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.

AT THIS POINT
After completing center crankcase components, proceed to Installing Right-Side Components, to Installing
Left-Side Components, and to Installing Top-Side Components.

HDX156A

3. Remove the plugs from the oil cooler lines and
connect to the appropriate fittings. Secure with
hose clamps and tighten securely.
4. Secure the front and rear driveshafts to the engine
flanges with the cap screws and tighten to 20 ft-lb;
then connect the upper and lower coolant hoses and
tighten the clamps securely.
5. Place a new grafoil
new grafoil seal on
pipe and install the
exhaust springs and
ft-lb.

seal in the cylinder head and a
the muffler end of the exhaust
exhaust pipe. Secure with two
two cap screws tightened to 20

Installing Engine/
Transmission
NOTE: Arctic Cat recommends new gaskets and Orings be installed whenever servicing the vehicle.

1. Using a suitable lifting sling and engine hoist,
lower the engine into the vehicle engaging the
slotted rear engine mount brackets with the engine
mounts; then install the front through-bolt.

HDX153A

2. Tighten the flange nuts on the rear cradle to 25 ftlb; then tighten the nut on the front through-bolt to
40 ft-lb.

HDX154

6. Install the O2 sensor and tighten the sensor to 19
ft-lb. Connect the harness to the sensor.
HDX157A

118

7. Install the forward exhaust pipe heat shield and
secure with the machine screws. Tighten securely.

700
HDX152A

HDX252A

8. Install the CVT cooling ducts on the V-bolt housing and secure with clamps. Tighten securely.
Install an appropriate nylon tie to secure the
exhaust duct.

500
HDX253A

11. On the left side, connect the ECT sensor connector, speed sensor connector, and spark plug cap.
HDX135A

9. Install the starter cable to the starter motor, secure
with the nut, and tighten securely; then secure the
engine/harness ground wires to the engine with a cap
screw and tighten to 8 ft-lb.

HDX135A

HDX149A

10. Properly position the gear position switch on the
engine (A to A and B to B); then secure the shift
cable bracket to the engine case and tighten the
engine case screws to 8 ft-lb. Connect the gear position switch connector.
HDX137A

12. Install the throttle body into the intake manifold boot
and secure with the clamp. Tighten to 30 in.-lb.

119

13. Install the air filter assembly and secure to the frame
with four sheet metal screws; then secure the intake
boot with the clamp and tighten securely.

16. Connect the MAP sensor connector (A), fuel injector
connector (B), ISC connector (C), and TPS connector
(D); then install new nylon ties as noted during removing.

HDX148A

HDX136A

14. Connect the IAT sensor connector to the IAT sensor and the crankcase breather tube to the crankcase; then install the air filter intake tube and
secure with a clamp and sheet metal screw.

17. Pour the recommended amount of oil and coolant
into the engine and radiator; then loosen the coolant bleed screw to allow trapped air to escape.
When clear coolant flows, tighten the bleed screw.

HDX031A

15. Connect the gasline hose to the throttle body making
sure the gasline hose connector fully engages and
locks onto the fuel rail.

HDX158B

18. Connect the negative battery cable to the battery.
19. Install the center skid plate, center floorboard, and
seat base; then install the seat back and seat.
20. Start the engine and check for leaks allowing to
warm up for several minutes; then shut the engine
off and check engine oil and coolant levels.

HDX138B

120

Fuel/Lubrication/Cooling
SPECIAL TOOLS

2. Remove the seat, seat back, and seat base; then disconnect the battery.
3. Remove the air inlet boot between the air filter and
throttle body; then disconnect the MAP sensor connector (A), fuel injector connector (B), and ISC connector (C).

p/n
0644-495
0644-275

NOTE: Special tools are available from the Arctic
Cat Service Department.

Electronic Fuel Injection

HDX048A

! WARNING
Whenever the gasline hoses are removed (other than for
pressure testing), the battery must be disconnected to
prevent inadvertent activation of the electronic fuel pump.

! WARNING
Whenever any maintenance or inspection is performed
on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames,
etc., in the area.

TROUBLESHOOTING
1. Verify that the electric fuel pump is operating by listening for a “whirring” sound for approximately
three 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.

HDX043A

4. Remove the screw from the throttle arm cover and
remove the cover; then loosen the jam nut and disconnect the throttle cable.

2. Check for a flashing EFI icon on the LCD. If EFI is
flashing, see EFI Diagnostic System in the Electrical
System 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 contamination. Clean or replace as necessary (see the Periodic
Maintenance section).
REMOVING THROTTLE BODY
1. Turn the ignition switch to the OFF position; then
remove the ignition switch key.

! WARNING
Do not turn the ignition switch to the ON position with
the hoses removed. Gasoline will be pumped by the
electric fuel pump causing a safety hazard.

HDX044A

5. Slowly disconnect the gasline hose connector from
the fuel rail.

! WARNING
Gasoline may be under pressure. Place an absorbant
towel under the connector to absorb any gasoline spray
when disconnecting.

121

FI092A

PR698A

6. Loosen the clamp securing the throttle body to the
intake manifold boot and remove the throttle body
assembly.

3. Remove the outer cap screw securing the front tank
hold-down; then swing the hold-down to the left.

7. Use tape to cover and seal the intake opening.

CAUTION
Any objects or liquid entering the intake opening will
fall into the engine causing severe damage if the engine
is turned over or started.

INSTALLING THROTTLE BODY
1. Install the throttle body into the intake manifold boot
and secure with the clamp. Tighten to 30 in.-lb.
2. Connect the throttle cable to the throttle body; then
connect the gasline hose.

PR167A

3. Connect the electrical connectors to the throttle body
components.
4. Install the air filter boot and secure with the existing
hardware.
5. Install the seat base, seat back, and seat.

Gas Tank
! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.

PR170

4. Remove four press-nuts securing the gas cap filler
panel; then remove the gas cap and panel. Install the
gas cap.

REMOVING
1. Remove the seat, seat back, and seat base; then
remove the floorboard.
2. Disconnect the vent hose (A), gasline hose (B), and
fuel pump/fuel level sensor connector (C); then cap
the vent fitting and gas hose fitting.

PR168

122

5. Remove the joining cap screw and nut from the rear
gas tank hold-down strap; then remove the inside
hold-down strap.

PR699A

2. Swing the front hold-down to the right into position and
install the cap screw and nut. Do not tighten at this time.
PR699A

6. Lift and slide the tank forward raising the front of the
tank first; then turn the tank and lift out the right
side.
CLEANING AND INSPECTING
1. Clean all gas tank components with parts-cleaning
solvent.
2. Inspect all hoses for cracks or leaks.
3. Inspect gas tank cap and tank for leaks, holes, and
damaged threads.
4. Inspect the fuel level sensor for proper operation (see
Electric Fuel Pump/Fuel Level Sensor in this section).

PR171

3. Install the rear hold-down strap joining cap screw and
nut. Do not tighten at this time.

INSTALLING

! 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.

1. Place the gas tank into position in the vehicle; then
install the inside rear hold-down strap.

PR699A

4. Place the gas cap filler panel into position; then if necessary, position the gas tank so the filler panel and filler
neck are not binding or rubbing.

PR173

PR176

123

5. Secure the filler panel with four press-nuts; then
tighten the hardware securing the hold-down straps
(from steps 2-3) securely.

Oil Filter/Oil Pump
NOTE: Whenever internal engine components
wear excessively or break and whenever oil is contaminated, the oil pump should be replaced.

TESTING OIL PUMP PRESSURE
NOTE: The engine must be warmed up to operating temperature (cooling fan cycling) for this test.

1. Remove the seat, seat back, and seat base.
PR166A

2. Using a suitable “T” fitting, connect Oil Pressure
Test Kit to the oil fitting and hose. Tighten all clamps
securely.
NOTE: Some oil seepage may occur when installing the oil pressure gauge. Wipe up oil residue
with a cloth.

3. Block the wheels, place the transmission in neutral,
and start the engine. Allow the engine to warm up to
operating temperature (with cooling fan cycling).
4. Connect a suitable tachometer. With the engine running at 3000 RPM, the pressure gauge must show
0.7-1.4 kg/cm2 (10-20 psi).
PR167A

6. Connect the vent hose (A) and gasline hose (B) to the
proper fittings; then connect the fuel pump/fuel level
sensor connector (C) to the main harness.

5. Remove the test kit and tachometer from the vehicle
and install the oil hose. Tighten the clamps securely.
6. Install the seat base, seat back, and seat.
NOTE: If the oil pressure is lower than specified,
check for an oil leak, damaged oil seal, or defective
oil pump.
NOTE: If the oil pressure is higher than specified,
check for too heavy engine oil weight (see General
Information - Gasoline - Oil Lubricant), clogged oil
passage, clogged oil filter, or improper installation
of the oil filter.

REMOVING/DISASSEMBLING

PR698A

7. Position the floorboard into the vehicle and secure
with the appropriate hardware; then install the seat
base, seat back, and seat.

Gas/Vent Hoses

1. Remove the oil pump from the engine (see RightSide Components in the Engine/Transmission section).
2. Remove the Phillips-head screw on the back side of
the pump and separate the pump housing and cover.
Note the position of the inner and outer rotors and
alignment pin for assembly.
3. Remove oil pump components.
CLEANING AND INSPECTING

Replace the gas hose every two years. Damage from
aging may not always be visible. Do not bend or obstruct
the routing of the vent hoses. Make certain the vent hoses
are securely connected and the opposite ends are always
open.
124

1. Clean all oil-pump components.
2. Inspect the rotors for scoring and gouges.
3. Inspect the alignment pin, driveshaft, and driven
sprocket for damage.

4. Inspect the pump housing and cover for cracks or
damage.
ASSEMBLING/INSTALLING
1. Place the rotors into the pump housing making sure
the alignment pin is in the groove of the rotor.
2. Place the cover onto the pump housing.
3. Secure the pump cover with the Phillips-head screw
coated with red Loctite #271. Tighten to 8 ft-lb.
4. Install the oil pump into the engine (see Right-Side
Components in the Engine/Transmission section).

Liquid Cooling System

PR182A

3. While lifting up on the front of the storage box, pry the
rear center clear of the center dash mount and remove
the storage box.

When filling the cooling system, use premixed Arctic Cat
Antifreeze. While the cooling system is being filled, air
pockets may develop; therefore, open the bleed screw on
the thermostat housing to allow air to bleed from the
cooling system. When clear coolant (no bubbles) is present, tighten the bleed screw securely; then fill the cooling
system to the bottom of the stand pipe in the radiator
neck. Run the engine for five minutes after the initial fill,
shut the engine off, and then “top-off” the cooling system
to the bottom of the stand pipe in the radiator neck.

CAUTION

PR186

After operating the vehicle for the initial 5-10 minutes,
stop the engine, allow the engine to cool down, and
check the coolant level. Add coolant as necessary.

4. Drain the coolant into a suitable container; then disconnect the cooling fan wire connector from the main harness.

Radiator
REMOVING
1. Remove the two sheet metal screws securing the
dash assembly to the frame (center front).
NOTE: Steps 1-3 are for models equipped with a
storage box only.
PR183A

5. Remove the two shoulder bolts and nuts securing the
radiator to the frame; then disconnect the upper and
lower coolant hoses.

HDX162A

2. Remove four torx-head screws (A) securing the underhood storage box to the frame; then remove two cap
screws with nuts (B) at the front of the storage box.

125

3. Open the high-point bleed screw on the thermostat
housing to allow trapped air to escape. Tighten
securely after filling.
4. Pour the recommended coolant into the radiator and
secure the radiator cap.
5. On models with a storage box, place the storage box
into position and using a smooth, flat pry-bar, pry the
center of the box past the dash mount; then secure
with the appropriate fasteners.

PR184A

6. Lift the radiator assembly from the vehicle. Account for
two upper and two lower rubber mounting grommets.
CLEANING AND INSPECTING
1. Flush the radiator with water to remove any contaminants.
2. Inspect the radiator for leaks and damage.
3. Inspect all hoses for cracks and deterioration.
4. Inspect all fasteners and grommets for damage or wear.
INSTALLING
1. Place the radiator into position making sure the grommets are correctly installed; then secure to the mounts
with the two shoulder bolts and nuts. Tighten securely.

PR187

6. Install the two sheet metal screws in the dash.
Tighten securely.
7. Start the engine and warm up to operating temperature; then verify the coolant level is at the bottom of
the stand pipe in the radiator neck. Add coolant as
necessary.

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 cylinder head. Account for a thermostat with seal.
PR184A

2. Connect the upper and lower coolant hoses to the
radiator and secure with the appropriate hose clamps;
then connect the cooling fan wire connector to the
main harness.

INSPECTING
1. Inspect the thermostat for corrosion, wear, or spring
damage.
2. Using the following procedure, inspect the thermostat for proper operation.
A. Suspend the thermostat in a container filled with
water.
B. Heat the water and monitor the temperature with a
thermometer.
C. The thermostat should start to open at 71.0-86.0°
C (160-187° F).
D. If the thermostat does not open, it must be
replaced.

PR183A

126

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 with seal into the thermostat
housing; then secure the thermostat housing to the
cylinder head with the two cap screws.

CAUTION
When installing the thermostat, make sure the bleed
holes are straight up and down or air will remain
trapped causing engine damage due to overheating.

PR122A

2. Drain the oil from the engine/transmission.
3. Remove the seat and seat base.
4. Loosen the coolant hose clamps and slide the clamps
away from the hose ends.

PR281A

2. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage.

Fan

PR132

5. Remove the two cap screws securing the water pump
to the engine; then remove the water pump.

REMOVING
1. Remove the radiator.
2. Remove the fan assembly from the radiator.
INSTALLING
1. Position the fan assembly on the radiator; then secure
with existing hardware.
NOTE: The fan wiring must be in the upper-right
position.

2. Install the radiator.
CC786A

Water Pump

INSTALLING
1. Secure the water pump to the engine with the two
cap screws tightened to 8 ft-lb.

 NOTE: The water pump is not a serviceable component. If the pump is defective or if the mechanical seal is leaking (coolant dripping from the
discharge hole), the water pump must be replaced.

REMOVING
1. Remove the radiator cap; then remove the water pump
coolant drain plug and drain the coolant.
127

The electric fuel pump and fuel level sensor are not serviceable components. If either component fails, it must
be replaced.
TESTING

! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.

AT THIS POINT
CC786A

2. Connect the two coolant hoses to the water pump and
secure with the clamps; then install the water pump
coolant drain plug.
3. Fill the engine/transmission with the proper amount
of recommended oil.
4. Open the coolant bleed screw and fill the cooling
system with the proper amount of recommended
coolant. Close the bleed screw and tighten when no
more air is present.

Prior to removing the electric fuel pump, the following
check should be performed to determine that removal is
necessary.

1. Turn the ignition switch ON and listen for a momentary “whirring” sound of the pump building pressure.
If the sound is heard (10 seconds), no electrical
checks are necessary. Turn the ignition switch OFF.
2. Disconnect the gasline hose from the fuel rail; then
install a suitable pressure gauge.

! WARNING
Gasoline may be under pressure. Place an absorbant
towel under the connector to absorb any gasoline spray
when disconnecting.

HDX158B

NOTE: While the cooling system is being filled,
air pockets may develop; therefore, run the engine
for five minutes after the initial fill, shut the engine
off, and then fill the cooling system.

5. Check the entire cooling system for leakage.

CAUTION
After operating the vehicle for the initial 5-10 minutes,
stop the engine, allow the engine to cool down, and
check the coolant level. Add coolant as necessary.

6. Install the seat base and seat.

Electric Fuel Pump/Fuel
Level Sensor
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in the Electrical System section).
128

FI092A

3. Turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pressure should read 3.0 kg/cm2 (43 psi).
4. If the pump is not running, disconnect the fuel pump/
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 voltage. If battery voltage is indicated and the fuel pump
does not run, replace the pump assembly. If no battery voltage is indicated, check the ECM and the
vehicle tilt sensor.

REMOVING

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.

1. Remove the key from the ignition switch.

! WARNING
Always ensure that power cannot be inadvertently
applied to the ignition/ECM when working on the fuel
system. If the ignition switch is turned on, the electric
fuel pump will start and gas could be rapidly pumped
and spilled resulting in fire and severe injury.

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).

2. Remove the seat, seat back, and seat base; then disconnect the negative battery cable.
3. Disconnect the electrical plug from the main harness;
then disconnect the gasline hose from the fuel pump.
4. Mark the fuel pump mounting and gas tank for
installing purposes; then remove the screws securing
the fuel pump to the gas tank and remove the fuel
pump.

CAUTION
Take care not to damage the float or float arm or
replacement of the entire assembly will be necessary.

5. Using duct tape or other suitable means, cover the
fuel pump opening.
INSPECTING

AT THIS POINT
If the pump has failed earlier test and must be replaced,
proceed to INSTALLING.

1. Inspect the fuel screen and blow clean with low pressure compressed air.
2. Move the float lever and check for free movement.
The float assembly should return to the lower position without force. If not, replace the fuel level sensor assembly.
3. Test the fuel level sensor by connecting a multimeter
(A) to the fuel level sensor leads (B); then select
OHMS. The multimeter should show 5 ohms at full
fuel position (C) and 95 ohms at empty fuel position
(D).

FI460A

B. Engage the tabs (C) of the fuel level sensor into
the mounting slot (B) and press toward the bottom
of the fuel pump to latch in place; then connect
the two-wire connector (A).
INSTALLING
1. Place the fuel pump assembly into the gas tank with
a new gasket aligning the match marks; then secure
with the four screws. Tighten securely.
NOTE: It is important to install the fuel pump with
the correct orientation to ensure adequate float
lever clearance.

2. Connect the gasline hose to the fuel pump pipe and
secure with the hose clamp; then connect the electrical plug to the main harness.
3. Connect the negative battery cable; then turn the
ignition switch to the ON position and verify that no
gas leaks are present, the pump runs for 2-3 seconds,
and the gas gauge reading is normal.
4. Start the engine to verify proper engine operation;
then shut off the engine and install the seat base, seat
back, and seat.

ATV2116

129

Troubleshooting
Problem: Starting impaired
Condition
1. Gas contaminated

Problem: Idling or low speed impaired
Condition
1. TPS out of adjustment

Problem: Medium or high speed impaired
Condition
1. High RPM “cut out” against RPM limiter

130

Remedy
1. Drain gas tank and fill with clean gas

Remedy
1. Adjust TPS

Remedy
1. Decrease RPM speed

Electrical System
NOTE: Certain components and sensors can be
checked by using the EFI diagnostic system and digital gauge (see EFI Diagnostic System in this section
for more information).

SPECIAL TOOLS
A number of special tools must be available to the technician when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appropriate tool description.
Description
Fluke Model 73 Multimeter
Fluke Model 77 Multimeter
Timing Light
MaxiClips
Peak Voltage Reading Adapter
Test Plug/Code List

p/n
0644-191
0644-559
0644-296
0744-041
0644-307
0486-219

NOTE: Special tools are available from the Arctic
Cat Service Department.

TESTING ELECTRICAL
COMPONENTS
All of the electrical tests should be made using the Fluke
Model 73 Multimeter or 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 troubleshooting
a specific component, always verify first the fuse(s) are
good, the bulb(s) are good, the connections are clean and
tight, the battery is fully charged, and all appropriate
switches are activated.
ELECTRICAL CONNECTIONS
The electrical connections should be checked periodically for proper function. In case of an electrical failure,
check fuses, connections (for tightness, corrosion, damage), and/or bulbs.

NOTE: Refer to all warnings and cautions provided
with the battery or battery maintainer/charger.

Loss of battery charge may be caused by ambient temperature, 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.

1. When charging a battery in the vehicle, be sure the
ignition switch is in the OFF position.
NOTE: Be sure to maintain the fluid of the battery at
the UPPER LEVEL. Use only distilled water when
adding fluid to these batteries.

2. Clean the battery terminals with a solution of baking
soda and water.
3. Be sure the charger and battery are in a well-ventilated area and ensure the battery charger cables will
not contact any battery acid. 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 terminal of the battery.
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.

Battery
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in this section)

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 procedures are recommended for cleaning and maintaining lead-acid batteries. Always read and follow instructions provided with
battery chargers and battery products.

800E

131

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.

RPM Limiter
NOTE: The ROV is equipped with an ECM that
cuts fuel delivery when maximum RPM is
approached. When the RPM limiter is activated, it
could be misinterpreted as a high-speed misfire.
NOTE: For absolute accuracy, all tests should be
made at room temperature of 68° F.

Switches

3300A

NOTE: Not using a battery charger with the proper
float maintenance will damage the battery if connected 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.
2. Be sure the charger and battery are in a well-ventilated area and ensure the battery charger cables will
not contact any battery acid. 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 terminal 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) illuminates.
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 authorized Arctic Cat dealer for further troubleshooting.
132

Each time the vehicle is used, switches should be
checked for proper operation. Use the following list
for reference.
A. Ignition/start switch — engine will run; starter
will engage.
B. Drive select switch — differential will engage
(4WD)/disengage (2WD).
C. Reverse/neutral/high/low/park switch — R/N/H/
L/P will be indicated on the LCD.
D. Headlight switch — high beam, low beam, and
lights off can be selected.
E. Brake switch — brakelight illuminates and starter
can be engaged with vehicle in gear.

Accessory Receptacle/
Connector
NOTE: This test procedure is for either the receptacles or the connectors.

VOLTAGE
1. Turn the ignition switch to the ON position; then set
the meter selector to the DC Voltage position.
2. Connect the red tester lead to the red/white wire or
the positive connector; then connect the black tester
lead to ground.
3. The meter must show battery voltage.
NOTE: If the meter shows no battery voltage,
troubleshoot the battery, fuse, receptacle, connector, or the main wiring harness.

Brakelight Switch
The switch connector is the two-prong black connector
below the master cylinder.
NOTE: The ignition switch must be in the ON
position.

VOLTAGE (Wiring Harness
Connector)
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the orange wire; then
connect the black tester lead to ground.

AR621D

3. When the lever is depressed, the meter must show
less than 1 ohm.
NOTE: If the meter shows more than 1 ohm of
resistance, replace the switch.

Engine Coolant
Temperature (ECT)
Sensor

PR276A

3. The meter must show battery voltage.
NOTE: If the meter shows no battery voltage,
troubleshoot the battery, fuse, switch, or the main
wiring harness.
NOTE: If the meter shows battery voltage, the
main wiring harness is good; proceed to test the
switch/component, the connector, and the switch
wiring harness for resistance.

NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in this section).

1. Connect the meter leads (selector in OHMS position)
to the sensor terminals.
2. Suspend the sensor and a thermometer in a container
of cooking oil; then heat the oil.
NOTE: Neither the sensor nor the thermometer
should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire
holders to suspend the sensor and thermometer.

RESISTANCE (Switch Connector)

CAUTION
Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.

NOTE: The brake pedal must be depressed for
this test.

1. Set the meter selector to the OHMS position.

! WARNING
Wear insulated gloves and safety glasses. Heated oil
can cause severe burns.

3. If the readings are not as indicated, the sensor must
be replaced.
MODEL
500

2. Connect the red tester lead to one black wire; then
connect the black tester lead to the other black wire.
700

OIL TEMPERATURE

OHMS

20 °C (68 °F)

2.45k

50 °C (122 °F)

800

80 °C (176 °F)

318

110 °C (212 °F)

142

40 °C (104 °F)

1136

100 °C (212 °F)

155

4. Install the sensor and tighten securely; then connect
the leads.

133

Fan Motor
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in this section).

2411-886

CAUTION

RESISTANCE (Fan Motor Connector)

Always replace a blown fuse with a fuse of the same
type and rating.

1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the red wire; then connect the black tester lead to the black wire.

NOTE: Make sure the fuses are returned to their
proper position according to amperage. Refer to
the amperage listed under each fuse on the power
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.

PR183A

3. The meter must show less than 1 ohm.
NOTE: If the meter shows more than 1 ohm of
resistance, troubleshoot or replace the fan motor.
NOTE: To determine if the fan motor is good, connect the red wire from the fan connector to a 12 volt
battery; then connect the black wire from the fan
connector to ground. The fan should operate.

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

Power Distribution
Module (PDM)
NOTE: The module and wiring harness are not a
serviceable component and must be replaced as
an assembly.

If there is any type of electrical system failure, always
check the fuses first.
NOTE: The fuses are located in a power distribution module under the operator’s seat.

1. Remove all fuses from the power distribution module.
NOTE: To remove a fuse, compress the locking
tabs on either side of the fuse case and lift out.
134

NOTE: Battery voltage will be indicated from only
one side of the fuse holder connector terminal; the
other side will show no voltage.
NOTE: When testing the HI fuse holder, the headlight OFF/HI/LO switch must be in the HI position;
when testing the LIGHTS fuse holder, the headlight
dimmer switch can be in either the HI or the LO position.
NOTE: If the meter shows no battery voltage,
troubleshoot the battery, switches, power distribution module, or the main wiring harness.

RELAYS
The 4-pin relays are identical plug-in type located on the
power distribution module. Relay function can be
checked by switching relay positions. The 4-pin relays
are interchangeable.

Ignition Coil
The ignition coil is mounted on the fuel pump mounting
plate adjacent to the fuel pump.
VOLTAGE (Primary Side)
See Primary Coil in this sub-section.

RESISTANCE

VOLTAGE
Primary Coil

CAUTION
Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.

1. Set the meter selector to the DC Voltage position;
then disconnect the two wires from the coil.

NOTE: For these tests, the meter selector should
be set to the OHMS position.

NOTE: The coil is located to the right of the
engine and may be accessed from behind the
right-side seat with the cargo box raised.

Primary Winding
1. Connect the red tester lead to the terminal (with the
wire removed); then connect the black tester lead to
ground.

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.

EFI Sensors/Components
CRANKSHAFT POSITION (CKP)
SENSOR
To test the CKP sensor, see Stator Coil/Crankshaft Position (CKP) Sensor in this section.
OXYGEN (O2) SENSOR
PR278A

2. The meter reading must be within specification.
Secondary Winding
1. Connect the red tester lead to the high tension lead
(with the plug cap removed); then connect the black
tester lead to either primary terminal.
2. The meter reading must be within specification.
NOTE: If the meter does not show as specified,
replace ignition coil.

The Oxygen Sensor (O2 Sensor) is located in the exhaust pipe.
NOTE: When testing the resistance of the sensor’s
heater, the engine/exhaust pipe must be at room temperature (65-75° F) or inaccurate readings will occur.

1. Open the cargo box; then remove the seat, air filter
cover, and air filter.
2. Remove the backrest and seat base.
3. Disconnect the sensor.

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.

HDX 247

NOTE: For this test, the meter must be in OHMS
position.

AR603D

2. The meter reading must be within specification.
NOTE: If the meter does not show as specified,
replace the spark plug cap.

5. On the sensor side of connector, connect the black (negative) test lead to one white wire pin; then connect the red
(positive) test lead to the other white wire pin. Readings
should be between 6.7 and 10.1 ohms.
NOTE: If the meter does not read as specified,
replace the sensor.
135

MANIFOLD ABSOLUTE PRESSURE/
INLET AIR TEMPERATURE (MAP/IAT)
SENSOR

700

NOTE: Preliminary checks may be performed on this
component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section).

1. Disconnect the MAP/IAT connector from the sensor
located on top of the throttle body.
2. Select DC Voltage on the tester and turn the ignition
switch to the ON position.
3. Connect the black tester lead to the black/pink wire and
the red tester lead to the orange/blue wire. The meter
should read 4.5-5.5 DC volts. If the meter does not read
as specified, check the ECM connector or wiring.

PR279A

3. Turn the ignition switch to the ON position.
4. The meter must show greater than 5 volts (500) or
approximately 6 volts (700).

4. Connect the MAP/IAT to the harness; then using MaxiClips, connect the red tester lead to the brown/white wire
and the black tester lead to the black/pink wire. With the
engine running at idle speed, the meter should read
approximately 2.5 DC volts (MAP sensor signal).

5. Leave the black tester lead connected; then connect the
red tester lead to the signal lead pin (S).

5. Connect the red tester lead to the green/red wire. With
the engine at idle and at room temperature (approximately 60° F), the meter should read approximately 2.9
DC volts.

NOTE: If the sensor tests are within specifications,
the LCD gauge must be replaced (see the Steering/
Frame/Controls section).

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

Speed Sensor

6. Slowly move the vehicle forward or backward; the meter
must show 0 and approximately 6 volts alternately.

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 sensor to the
sensor housing.
2. Remove the sensor from the sensor housing accounting
for an O-ring.

NOTE: Preliminary checks may be performed on this
component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section).

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.

NOTE: Prior to testing the speed sensor, inspect the
three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion.

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).
500

CD071

KC248A

136

Electronic Power
Steering (EPS)

The EPS system is battery-system powered; therefore, the
battery must be in good condition and fully charged.
Power delivery and overload protection are provided by an
EPS relay and 30-amp fuse, located under the seat in the
Power Distribution Module (PDM).

Certain models were produced with electronic power steering. The EPS system is an electro-mechanical device that
utilizes 12 volt DC power to drive a motor linked to the
steering shaft to assist the driver when rotating the steering
wheel. Driver steering inputs are detected by a torque-sensing transducer assembly within the EPS housing. These
inputs are converted to electronic signals by the transducer
and control circuitry to tell the motor which way to drive the
steering shaft. When no steering input (pressure on the
steering wheel) is detected, no torque signal is generated,
and no steering assist is provided by the motor.

If a system malfunction occurs, a diagnostic trouble code
(DTC) will be displayed on the LCD gauge. Initially, the
gauge will go blank for 30 seconds and the code will flash;
then the gauge will return to normal except the code will
continue to be displayed.

137

Code

Fault Description

Fault Condition

EPS Fault Recovery Method

Internal EPS Condition

Correct EPS condition*

C1302

Internal EPS Condition

Correct EPS condition*

Internal EPS Condition

Correct EPS condition*

Internal EPS Condition

Correct EPS condition*

Internal EPS Condition

Correct EPS condition*

C1303
C1304
C1305
C1306
C1307
C1308
C1309
C1310
C1311
C1312
C1313
C1314
C1315
C1316
C1317
C1318
C1319
C1320
C1321
C1322
C1323
C1324
C1325
C1326
C1327
C1328
C1329

EPS internal over-current condition
has been detected
Excessive Current Error EPS internal current measurement
error has been detected
Torque Sensor Range EPS internal torque sensor range conFault
dition has been detected
Torque Sensor Linearity EPS internal torque sensor linearity
Fault
condition has been detected
Rotor Position Encoder EPS internal rotor position encoder
condition has been detected
System Voltage Low
EPS battery power low-voltage condition has been detected

Possible Cause

C1301 Over Current

System voltage low (less than 11 VDC at the EPS will auto-recover when the batEPS). Wire harness issue, faulty voltage regu- tery supply returns to normal
lator, weak battery or loose battery terminals.
System Voltage High EPS battery power over-voltage condi- System voltage high (more than 16 VDC at
EPS will auto-recover when the battion has been detected
the EPS). Wire harness issue, faulty voltage tery supply returns to normal
regulator or loose battery terminals.
Temperature Above
EPS internal 110o C over-temp condi- Clean the EPS housing and cooling fins.
EPS will auto-recover when internal
110° C
tion has been detected
temperature drops below 105° C
Temperature Above
EPS internal 120o C over-temp condi- Clean the EPS housing and cooling fins.
EPS will auto-recover when internal
120° C
tion has been detected
temperature drops below 115° C
Vehicle Speed High
Vehicle speed signal received by the Intermittent main harness wires, defective
EPS will auto-recover when the vehiEPS exceeds the maximum speed
speed-sensor, or intermittent speed sensor
cle speed signal drops below the
specification
wires.
maximum speed specification
Vehicle Speed Low
Vehicle speed signal received by the Broken main harness wires, defective speed- EPS will auto-recover when the vehiEPS is zero or missing
sensor, or broken speed sensor wires.
cle speed signal returns to normal
Vehicle Speed Faulty Vehicle speed CAN signal received by Broken main harness CAN wires, defective
EPS will auto-recover when the vehithe EPS incorrect or missing
speed-sensor, or broken speed sensor wires. cle speed signal returns to normal
Engine RPM High
Engine RPM signal received by the
Intermittent main harness RPM wires, inter- EPS will auto-recover when engine
EPS exceeds the maximum RPM
mittent voltage regulator, intermittent ACG sta- RPM signal drops below the maxispecification
tor wires.
mum RPM specification
Engine RPM Low
Engine RPM signal received by the
Handlebar switch in the "OFF" position, bro- EPS will auto-recover when engine
EPS suddenly dropped below 500
ken main harness RPM wires, defect voltage RPM signal returns to normal
RPM
regulator, broken ACG stator wires.
Engine RPM Faulty
Engine RPM CAN signal received by Broken main harness CAN wires or defective EPS will auto-recover when engine
the EPS incorrect or missing
ECM.
RPM signal returns to normal
EEPROM Error
EPS internal memory error has been Internal EPS condition
Correct EPS condition*
detected
CAN Bus Error
The EPS has lost CAN communication Broken CAN wires in the main harness. EFI Correct EPS condition*
with the EFI ECM
ECM connector has been disconnected.
Internal CRC Error
EPS internal CRC calculation condition EPS reflash has failed. Battery power was
EPS must be reprogrammed
has been detected
lost, or the keyswitch was turned off, during
EPS reflash programming.
Boot Counter Exceeded EPS internal application code condi- Intermittent power has prevented a successful Correct EPS power condition*
tion has been detected
application code launch.
Incorrect Vehicle
Vehicle speed signal received by the Intermittent or broken main harness RPM
Correct EPS condition*
Speed-to-RPM Ratio
EPS exceeds 10 MPH, but the engine wires, intermittent voltage regulator, intermitRPM signal less than 500 RPM
tent or broken ACG stator wires.
Vehicle Speed Erratic Vehicle speed signal received by the Intermittent main harness, intermittent speed Correct EPS vehicle speed signal
EPS changing at an unrealistic rate
sensor, dirty speed senor or trigger wheel.
condition*
Engine RPM Lost
Engine RPM signal received by the
Handlebar switch in the "OFF" position, bro- EPS will auto-recover when engine
EPS exceeds 500 RPM and then is
ken main harness RPM wires, defect voltage RPM signal returns to normal
zero or missing
regulator, broken ACG stator wires.
"EPS OFF" Gauge Dis- Battery power has been applied to the The EPS has been automatically disabled,
EPS will auto-recover when engine
play
EPS for more than 5-minutes, but no after 5-minutes of inactivity, to conserve bat- is started or the keyswitch is cycled
engine RPM signal has been detected tery power.
On-Off-On
Loss of CAN communi- The gauge has lost CAN communica- Broken CAN wires in the main harness or dis- Gauge DTC display will clear when
cation with EPS unit
tion with the EPS
connected EPS. This is not an EPS generated the EPS-to-gauge CAN communicaDTC; gauge DTC display only.
tion is restored.
Dual Loss
EPS loss of both the vehicle speed and Handlebar switch in the "OFF" position, the
EPS will auto-recover when either
the engine RPM signals has been
engine stalled (keyswitch "ON"), broken har- the vehicle speed or engine RPM
detected
ness wires, loss of CAN data signal.
signal is restored.
Rotor Position Encoder EPS internal rotor position encoder
Internal EPS Condition
Correct EPS condition*
variance condition has been detected
Voltage Converter Error EPS internal voltage converter lowInternal EPS Condition
Correct EPS condition*
(Low)
voltage condition has been detected
Voltage Converter Error EPS internal voltage converter over- Internal EPS Condition
Correct EPS condition*
(High)
voltage condition has been detected
Internal Data Error
EPS internal preloaded data condition Internal EPS Condition
EPS must be reprogrammed
has been detected

* After correcting the condition, cycle the key switch On-Off-On

138

The following tests may help in determining the source
of a code:
NOTE: The EPS assembly is not serviceable and
must not be disassembled or EPS warranty will be
voided. Make sure to thoroughly troubleshoot the
entire system before replacing the EPS assembly

Condition: Ignition Key Switch ON and NO EPS assist
when moving the steering wheel. Code flashing.
NOTE: Prior to troubleshooting below, make sure
the Ignition Key Switch has not been left on with the
engine not started. After five minutes, this will deactivate the EPS and display the code. Turn the Ignition
Key Switch OFF and back to ON to reset and reactivate the EPS. If code and symptom persists, continue
as follows:

1. Check 30-amp EPS fuse.
2. Check EPS relay (may be switched with any other 4pin relay on PDM - replace relay if EPS normal after
switching).
3. Disconnect 2-pin connector on the EPS assembly
and connect a volt meter set to DC voltage to the harness (black meter lead to BLK and red meter lead to
ORG/BRN).With the ignition switch to the ON position, the meter must read more than 8.5 DC volts (if
correct voltage is not present, check connections and
wiring harness - if correct voltage is present, replace
EPS assembly - see the Steering/Frame/Controls section).

CAUTION
Do not attempt to check resistance of the EPS motor (2-pin
input receptacle). There are internal capacitors holding a
charge that can cause internal damage to an ohmmeter.

If after completing the above check with normal results
and a code persists, the EPS assembly must be replaced
(see the Steering/Frame/Controls Section).

Ignition Switch
To access the ignition switch, dash switches, front accessory connectors, and front switched accessory connector,
the dash must be unfastened and slid to the rear.
VOLTAGE
1. Set the meter selector to the DC Voltage position.
2. Connect the red meter lead to the red wire; then connect the black meter lead to ground.

4. Connect the red meter lead to the red/black wire;
then with the black lead grounded, turn the ignition
switch to the ON position. The meter must show battery voltage.
5. Connect the red meter lead to the yellow/green wire;
then with the black lead grounded, turn the ignition
switch to the START position. The starter should
engage and the meter must show battery voltage.
NOTE: When the starter is engaged, battery voltage will be approximately 10.5 DC volts.

Headlight Switch
VOLTAGE
1. Connect the red meter lead to the gray wire; then
connect the black meter lead to the black wire.
2. Turn the ignition switch to the ON position. The
meter must show battery voltage.
NOTE: If the meter does not show battery voltage, troubleshoot the LIGHTS fuse on the power
distribution module, the ignition switch, or the
main harness.

3. Connect the red meter lead to the yellow wire; then
select the high beam position on the headlight
switch. The meter must show battery voltage.
4. Connect the red meter lead to either of the two white
wires; then select the low beam position on the headlight switch. The meter must show battery voltage.
NOTE: The battery voltage will show lower in steps
3 and 4 due to electrical loading of the headlights.

Drive Select Switch
RESISTANCE
1. Remove the switch assembly from the dash; then disconnect the harness from the switch.
NOTE: The switch can be removed from the dash
using a thin, flat pry bar or suitable putty knife. It is not
necessary to remove the dash to remove the switch.

2. Using an ohmmeter, the following readings must be
observed.

3. Meter must show battery voltage.
NOTE: If the meter shows no battery voltage,
troubleshoot the main 30 amp fuse, the battery, or
the main wiring harness.

139

3. Select 4WD on the drive select switch. The meter
must show approximately 5 DC volts.
4. Depress the reverse override switch. The meter must
show approximately 1.5 DC volts.
5. Connect the red meter lead to the red/yellow wire.
The meter must show approximately 1.5 DC volts.
Depress the reverse override switch. The meter must
show approximately 1.5 DC volts.
6. Connect the red meter lead to the red/green wire. The
meter should show 0 DC volts.
PR566A

2WD

4WD

A to D <1 ohm

C to E <1 ohm

A to B Open

A to B <1 ohm

DIFFERENTIAL LOCK

A to C Open

A to C <1 ohm

A to E Open

A to B <1 ohm

A to C <1 ohm

VOLTAGE
NOTE: Voltage tests must be made with the
switch and the actuator connected. The meter can
be connected at the actuator connector using a
break-out harness or MaxiClips.

1. Connect the black tester lead to the black wire; then
turn the ignition switch to the ON position.
2. Select the DC Volts position on the tester and
observe the meter readings for each of the three
switch positions.
WIRE COLOR

2WD

4WD

Black to Orange 12.0 DC Volts 12.0 DC Volts
Black to White/ 11.5 DC Volts
Green

7. Depress the reverse override switch. The meter must
show approximately 5 DC volts.

0 DC Volts

Black to White/ 11.5 DC Volts 11.5 DC Volts
Red

Front Drive Actuator
NOTE: With the engine stopped and the ignition
switch in the ON position, a momentary “whirring”
sound must be noticeable each time the drive
select switch is moved to 2WD and 4WD. Test the
switch, 30 amp fuse, and wiring connections prior
to testing the actuator.
NOTE: The differential must be in the unlocked
position for this procedure.

VOLTAGE
1. Locate the 4-wire connector for the front drive selector actuator on the frame to the right of the differential; then connect the red meter lead to the orange
wire using a MaxiClip.

DIFFERENTIAL LOCK
12.0 DC Volts
0 DC Volts
0 DC Volts

NOTE: If the meter does not show voltages according to the chart, make sure the front drive actuator is
plugged in; then troubleshoot the switch, ignition
fuses, battery connections, or wiring harness.

Reverse Override Switch
VOLTAGE
NOTE: To perform the following tests, the ignition
switch must be in the ON position and the transmission shifted into reverse gear.

1. Connect the red meter lead to the black/blue wire and
the black meter lead to a suitable ground; then select
2WD on the drive select switch. The meter must
show approximately 1.5 DC volts.
2. Depress the reverse override switch. The meter
showing should not change from step 1.
140

PR293

2. Connect the black lead to the black wire using a MaxiClip; then select 2WD on the drive select switch.

3. With the vehicle in neutral and the engine running as
shown in the chart (with the headlights on), the meter
must show 14-15.5 DC volts.
MODEL

RPM

500

3000

700

5000

CAUTION
Do not run the engine at high RPM for more than 10 seconds.

PR295

NOTE: The black tester lead can remain connected to the black wire for the remaining tests.

3. Turn the ignition switch to the ON position. The
meter must show battery voltage.

NOTE: If voltage is lower than specified, test AC
Generator - No Load.

VOLTAGE (AC Generator No Load)
The connector is the black three-pin one on the right side
below the ignition coil.

NOTE: If battery voltage is not shown, troubleshoot the 10 amp ignition (IGN) fuse on the power
distribution module, the ignition switch, or the
main wiring harness.

4. Connect the red meter lead to the white/red wire. The
meter must show battery voltage.
5. Select 4WD on the drive select switch. The meter
must show 0 DC volts.
6. Connect the red meter lead to the white/orange wire.
The meter must show battery voltage.
7. Engage the differential lock. The meter must show 0
DC volts.
NOTE: If the meter does not show 0 DC volts,
rock the vehicle to help engage the differential
lock; then troubleshoot the differential lock switch.

Stator Coil/Crankshaft
Position (CKP) Sensor
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in this section).

VOLTAGE (AC Generator - Regulated
Output)
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the positive battery
post; then connect the black tester lead to the negative battery post.

HDX150A

NOTE: Test the connector coming from the
engine.

1. Set the meter selector to the AC Voltage position.
2. Test between the three yellow wires for a total of
three tests.
3. With the engine running at a constant 5000 RPM, all
wire tests must be within specification

CAUTION
Do not run the engine at high RPM for more than 10 seconds.

NOTE: If both stator coil tests failed, check all
connections, etc., and test again. If no voltage is
present, replace the stator coil assembly.

RESISTANCE (AC Generator)

CAUTION
Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.

1. Set the meter selector to OHMS position.
2. Test between the three yellow wires for a total of
three tests.
141

3. The meter reading must be within specification.
RESISTANCE
(Crankshaft Position Sensor)
1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the brown wire; then
connect the black tester lead to the white wire. The
meter reading must be within specification.

NOTE: The ignition switch must be in the ON 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
battery voltage and the starter should operate.

AC VOLTAGE
NOTE: The battery must be at full charge for
these tests.

Crankshaft Position Sensor
1. Set the meter selector to the AC Voltage position.
2. Connect the red tester lead to the brown wire; then
connect the black tester lead to the white wire.
3. Crank the engine over using the electric starter.
4. The meter reading must be within specification.
AR607D

Starter Motor
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in this section).
NOTE: The starter motor is not a serviceable
component. If the starter is defective, it must be
replaced.

REMOVING
1. Disconnect the battery.

CAUTION
Always disconnect the negative battery cable from the
battery first; then disconnect the positive cable.

2. Remove the nut securing the positive cable to the starter;
then remove the cable from the starter.

NOTE: If the meter showed battery voltage but
the starter did not operate or operated slowly,
inspect battery voltage (at the battery), starter condition, and/or ground connections.
NOTE: If the meter showed no battery voltage,
inspect the main fuse, ground connections, starter
lead, battery voltage (at the battery), starter relay,
or the neutral start relay.

Starter Relay
1. Remove the seat base and battery cover; then using
the multimeter set to the DC Voltage position, check
the relay as follows.
2. Connect the red tester lead to the positive battery terminal; then connect the black tester lead to the starter
cable connection on the starter relay. The meter must
show battery voltage.

3. Remove the two cap screws securing the starter with
ground wires to the crankcase; then remove the starter.
Account for the wiring forms and 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 machine screws and wiring forms.
2. Secure the positive cable to the starter with the nut.
3. Connect the battery.
TESTING VOLTAGE
Perform this test on the starter positive terminal. To access
the terminal, slide the boot away.
142

PR296

NOTE: Make sure the ignition switch is in the ON
position, transmission in neutral, and parking brake
set.

3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts and a
“click” should be heard from the relay.
NOTE: If a “click” is heard and more than one volt is
indicated by the multimeter, replace the starter relay. If
no “click” is heard and the multimeter continues to
indicate battery voltage, proceed to step 4.

4. Disconnect the two-wire plug from the starter relay; then
connect the red tester lead to the green wire and the
black tester lead to the black wire.

Regulator/Rectifier
NOTE: Preliminary checks may be performed on this
component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section).

The regulator/rectifier is located under the seat next to the
battery. Try to verify all other charging system components
before the regulator/rectifier is replaced.
TESTING VOLTAGE
1. Start engine and warm up to normal operating temperatures; then connect a multimeter (set at the DC Voltage
position) to the battery as follows.
2. Connect the red tester lead to the positive battery post
and the black tester lead to the negative battery post.
3. Slowly increase RPM. The voltage should increase with
the engine RPM to a maximum of 15.5 DC volts.
NOTE: If voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or corroded. Clean and tighten battery connections or
replace the regulator/rectifier. If voltage does not rise,
replace the regulator/rectifier.

PR297A

5. Depress the starter button and observe the multimeter.

Headlights

NOTE: If battery voltage is indicated, replace the
starter relay.

The connectors are the four 2-prong ones secured to the
headlight bulbs (two on each side).

Electronic Control Module
(ECM)
The ECM is located beneath the seat near the battery.
NOTE: The ECM is not a serviceable component. If
the unit is defective, it must be replaced.

The ECM is rarely the cause for electrical problems; however, if the ECM is suspected, substitute another ECM to verify the suspected one is defective.

VOLTAGE
NOTE: The low beams are the outside bulbs (black
and white wires) and the high beams are the inside
bulbs (yellow and black wires). Always connect the
black tester lead to the black wires. The ignition
switch must be in the ON position.

1. Set the meter selector to the DC Voltage position.
2. Set the light switch to the correct position for the
affected light; then connect the black tester lead to the
black wire using a MaxiClip.

This EFI system has a built-in feature that will only allow
an ECM of the same part number to be used in this
model. Do not attempt to substitute an ECM from a different model as the system will not allow it to start.

3. Connect the red tester lead to the yellow wire (high
beam) or white wire (low beam) using a MaxiClip. The
meter must show battery voltage.

Error codes can be cleared by following the procedures
located in the EFI Diagnostic System sub-section in this
section.

NOTE: If battery voltage is not shown in any test,
inspect the LIGHTS fuse on the power distribution
module, headlight switch, ignition switch, switch
connectors, or wiring harness.

143

Taillight-Brakelight
VOLTAGE (Taillight)
NOTE: Perform this test at the socket end of the
taillight-brakelight harness (pigtail). The ignition
switch must be in the ON position and either high
beam or low beam selected on the light switch.

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. The
meter should show battery voltage.
3. With the ignition key in the LIGHTS position, the
meter must show battery voltage.

If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil bracket may
be bent or damaged, or the ECM may be faulty.

EFI Diagnostic System
DIGITAL GAUGE
The digital gauge can be used as a diagnostic tool for
many of the DTC’s displayed. To place the gauge into the
diagnostic mode, use the following procedure.
1. Turn the ignition switch ON.
2. Depress and hold both Mode and Set buttons
together for approximately 10 seconds after which
the letters “dIAg” will appear on the LCD momentarily followed by COOL.

NOTE: If battery voltage is not shown and the
headlights are illuminated, inspect the three-wire
connector in the left-rear canopy tube at the juncture of the canopy tube and lower frame. If battery
voltage is shown on the meter, replace the bulb.

VOLTAGE (Brakelight)
NOTE: Perform this test at the socket end of the
taillight-brakelight harness (pigtail). The ignition
switch must be in the ON position.

1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the red/blue wire; then
connect the black tester lead to the black wire.
3. With the brake applied, the meter must show battery
voltage.
NOTE: If the meter shows no voltage, inspect the
10 amp ignition (IGN) fuse, brakelight switch, wiring harness, or connectors.

EFI002A

NOTE: The display on the gauge will display in
SAE (speedometer in MPH mode) or Metric (speedometer in km/h mode), For example to read temperature in degrees Celsius, select km/h mode on
the gauge or to read Fahrenheit, select MPH mode.

3. Cycle the display by depressing either the Set or
Mode button to step to the desired function.

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.
NOTE: To check ignition timing, the seat, seat
back, and seat base must be removed.

1. Attach the Timing Light to the spark plug high tension lead; then remove the timing inspection plug
from the left-side crankcase cover.
2. Start the engine and using the RPM function on the
speedometer/tachometer, run at 1500 RPM; ignition
timing should be 10° BTDC.
3. Install the timing inspection plug.

144

EFI004

NOTE: The gauge can be utilized dynamically
(engine running/vehicle moving) or statically
(engine/vehicle stopped).

Examples of Static checks: Battery voltage, fuel gauge/
sensor, and TPS (0% @ closed throttle, 95-100% @
WOT).

2. High Temperature indicator (on @ 230 degrees F).
3. Thermostat opening @ approximately 180 degrees F,
indicated by a momentary drop or pause in the rising
temperature reading.
4. Fan ON @ 185 degrees F, OFF @ 175 degrees F.
A. fan motor
B. fan relay
C. fan fuse
D. wiring connections
5. High Temperature Rev Limiter 5000 RPM @ 230
degrees F.
Fuel Sensor (FUEL) Diagnostic Mode

EFI007

Examples of Dynamic checks: Battery charging, coolant
temperature including fans ON/OFF (see below), MAP/
IAT, tachometer, and speedometer signal.

EFI010

Display: Fuel level signal from the fuel level sensor (measured in ohms).
DTC: C1400, C1401, C1402
EFI003
*Fan Schedule: Fan ON @ 185 degrees F, OFF @ 175 degrees F.
*High Temperature REV Limiter 5000 RPM @ 230 degrees F.
*Thermostat opens @ approximately 180 degrees F noted by a 2-5
degree drop momentarily.

Coolant (COOL) Diagnostic Mode

Usage: Check output of the fuel level sensor
1. Full fuel is indicated by a reading of 86-100 ohms
2. Empty is indicated by a reading of 0-5 ohms
* 110-500 ohms, suspect the fuel level sensor or wiring
* 0-100 ohms but no fuel gauge indication, suspect the fuel gauge

Tachometer (tACH) Diagnostic
Mode

EFI 003

Display: Engine coolant temperature as measured by the
ECT sensor.

EFI009

Display: Engine RPM

DTC: P0116, P0117, P0118, P0119

DTC: P0336, P0337, P0339

Usage: Monitor coolant temperature to verify the following.

Usage: Verify engine speed signal from the following.

1. ECT sensor signal

1. CKP (crankshaft position) sensor to ECM
2. ECM (CAN) signal to gauge (tachometer)
145

MAP (bArO) Diagnostic Mode

3. ECM (CAN) signal to EPS
Speed (SPd) Diagnostic Mode

EFI006

Display: vehicle speed signal.

Display: MAP in millibars (1013 millibar = 29.92 in.
mercury).

DTC: P0500

DTC: P0107, P0108

Usage: verify speedometer sensor signal from the following.

Usage: Verify barometric pressure signal correct.

EFI008

1. Speed sensor to ECM.
2. ECM (CAN) signal to gauge (speedometer/odometer).
3. ECM (CAN) signal to EPS unit.
TPS (tPS) Diagnostic Mode

Note: Local barometric pressure is given in in./
Hg (Inches of Mercury). 34 millibars are equal to 1
inch of mercury. Example: (Gauge reading in the
BARO mode = 974 millibars, thus 974/34 = 28.64
in./Hg). Second example: (Local barometer reading
is 29.87 in./Hg, therefore 29.87 X 34 = 1015 millibars) The gauge should be reading very close to
1015.

Inlet Air Temperature (AIr)
Diagnostic Mode

EFI007

Display: % of TPS (0% closed, 95-100% WOT).
DTC: P0121, P0122, P0123
Usage: Verify TPS signal and adjust throttle cable.

EFI005

Display: Inlet air temperature in Fahrenheit or Celsius.
DTC: P0112, P0113, P0114
Usage: Verify correct output of IAT sensor.
NOTE: After engine has been running, IAT readings will be higher than outside air temperature
due to engine and engine compartment heat as
well as intake manifold heating.

146

Battery (bAtt) Diagnostic Mode

4. Battery voltage starter cranking (10.5-11.5 VDC).
DIAGNOSTIC TROUBLE CODES
(DTC)
If an EFI or related chassis component fails or an out-oftolerance signal is detected by the ECM, a diagnostic
trouble code (DTC) will be generated in the ECM and
displayed on the LCD. The DTC will be displayed
alternately with a wrench icon or malfunction indicator
light (MIL). The DTC will continue to flash, until the
malfunction is corrected and the code cleared.
Code List
EFI004

Display: System DC voltage.
DTC: P0562, P0563, P2531, P2532
Usage: Verify system voltage under following conditions.
1. Battery voltage with engine and accessories off
(>12.2 VDC for fully charged).
2. Battery voltage with engine running (charging = 13.8
VDC or greater).

NOTE: Each of the following numerical codes will
have a one-letter prefix of C, P, or U. A “C” prefix
denotes a chassis malfunction, a “P” prefix
denotes a power train malfunction, and a “U” prefix denotes a loss of communication with the
gauge.
NOTE: Normal malfunction codes are cleared from
the LCD when the component is replaced or the malfunction is corrected; however, intermittent codes
must be cleared as noted in the code chart.

3. Battery voltage with electrical accessories operating,
engine idling (13.5 VDC or greater).
Code

Fault Description

C0063
C0064
P0030
P0031
P0032
P0107
P0108
P0112
P0113
P0114
P0116
P0117
P0118
P0119
P0121
P0122
P0123
P0130
P0131

Tilt Sensor Circuit High
Tilt Sensor Circuit Low/SG/Open
O2 Heater Intermittent/Open
O2 Heater Low/SG
O2 Heater High/SP
MAP Sensor Circuit Low/SG/Open
MAP Sensor Circuit High/SP
IAT Sensor Circuit Low/SG
IAT Sensor Circuit High/Open
IAT Sensor Circuit Intermittent
ECT Sensor Circuit Range/Performance
ECT Sensor Circuit Low/SG
ECT Sensor Circuit High/Open/SP
ECT Sensor Circuit Intermittent
TPS Range/Performance
TPS Circuit Low/SG
TPS Circuit High
O2 Sensor Intermittent/Open
O2 Sensor Low/SG or Air-Leak

P0132
P0171
P0172
P0219

O2 Sensor High/SP
O2 Feedback Below Minimum Correction
O2 Feedback Exceeds Maximum Correction
Engine Over-Speed Condition

P0231

Fuel Pump Relay Circuit Low/SG/Open

P0232
P0233
P0261
P0262
P0263
P0264
P0265
P0266
P0336

Fuel Pump Relay Circuit High
Fuel Pump Relay Circuit
Rear Cylinder Fuel injector Circuit Low/SG
Rear Cylinder Fuel injector Circuit High
Rear Cylinder Fuel injector Balance/Open
Front Cylinder Fuel injector Circuit Low/SG
Front Cylinder Fuel injector Circuit High
Front Cylinder Fuel injector Balance/Open
Crankshaft Angle Sensor Synchronization

Possible Cause

Fault Recovery Method

Sensor or interconnect harness shorted to battery power
Sensor or interconnect harness open or shorted to chassis ground
Heater or interconnect harness intermittent or open
Heater or interconnect harness shorted to chassis ground
Heater or interconnect harness shorted to battery power
Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness shorted to battery power
Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness open or shorted to battery power
Sensor or interconnect harness intermittent
Sensor producing an out-of-range voltage
Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness open or shorted to battery power
Sensor or interconnect harness intermittent
Sensor producing an out-of-range voltage
Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness open or shorted to battery power
Sensor or interconnect harness intermittent or open
Sensor or interconnect harness shorted to chassis ground or an airleak exists
Sensor or interconnect harness shorted to battery power
Low fuel rail pressure, dirty fuel filter, or dirty injectors
Excessive fuel rail pressure, MAP or temp sensors out-of-spec

Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*

Engine speed (RPM) has exceeded the ECM over-speed setpoint/
limit
Relay has been removed or interconnect harness shorted to chassis
ground
Relay or interconnect harness shorted to battery power
Relay circuit erratic or intermittent
Injector or interconnect harness shorted to chassis ground
Injector or interconnect harness shorted to battery power
Injector has been disconnected or interconnect harness open
Injector or interconnect harness shorted to chassis ground
Injector or interconnect harness shorted to battery power
Injector has been disconnected or interconnect harness open
Sensor or interconnect harness intermittent

Reduce engine speed

Correct condition*
Correct condition*
Correct condition*

Correct condition*
Correct condition*
Correct condition*
Correct condition**
Correct condition**
Correct condition**
Correct condition**
Correct condition**
Correct condition**
Correct condition**

147

Code
P0337
P0339
P0340
P0341
P0342
P0480
P0481
P0482
P0483
P0484
P0485

Fault Description
Crankshaft Angle Sensor Circuit/SG
Crankshaft Angle Sensor Intermittent/
Erratic
Camshaft Angle Sensor Synchronization
Camshaft Angle Sensor Circuit/SG
Camshaft Angle Sensor Intermittent/Erratic
Fan-Primary/Right Relay Control Circuit
Fan-Secondary/Left Relay Control Circuit
High
Fan-Secondary/Left Relay Control Circuit
Low/SG/Open
Fan-Secondary/Left Relay Control Circuit
Fan-Primary/Right Relay Control Circuit
High
Fan-Primary/Right Relay Control Circuit
Low/SG/Open
Vehicle Speed-Sensor

Possible Cause

Fault Recovery Method

Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness intermittent

Correct condition**
Correct condition**

Sensor or interconnect harness intermittent
Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness intermittent
Relay erratic or intermittent
Relay or interconnect harness shorted to battery power

Correct condition**
Correct condition**
Correct condition**
Correct condition*
Correct condition*

Secondary fan fuse has blown, the secondary fan relay has been
removed or interconnect harness shorted to chassis ground
Relay erratic or intermittent
Relay or interconnect harness shorted to battery power

Correct condition*
Correct condition*
Correct condition*

Primary fan fuse has blown, the primary fan relay has been removed Correct condition*
or interconnect harness shorted to chassis ground
P0500
Sensor circuit signal intermittent or missing
Correct condition*, start
and drive the vehicle*
P0508
IAC System Circuit Low/SG
IAC interconnect harness shorted to chassis ground
Correct condition*
P0509
IAC System Circuit High/Open
IAC disconnected or the interconnect harness shorted to battery
Correct condition*
power
P0520
Engine Oil Sensor/Switch
Sensor or interconnect harness erratic or intermittent
Correct condition*
P0562
System Voltage Low
Battery charge condition low or the regulator/rectifier output low
Correct condition*
P0563
System Voltage High
Battery cable connections are loose or the regulator/rectifier output Correct condition*
high
P0601
ECU Memory Check-Sum Error
Reflash the ECM with the current software version
Correct ECM software
issue*
P0615
Starter Relay Circuit
Start switch/button, starter relay, gearswitch or interconnect harness Correct condition*
erratic or intermittent
P0616
Starter Relay Circuit Low
Start switch/button, starter relay or interconnect harness intermittent Correct condition*
or shorted to chassis ground
P0617
Starter Relay Circuit High
Start switch/button, starter relay or interconnect harness intermittent Correct condition*
or shorted to battery power
P0630
VIN Not Programmed or Incompatible
Verify the LCD gauge and ECM part numbers are correct for the vehi- Correct gauge and ECM
cle model number and VIN
VIN compatibility issue*
P0642
Sensor Power Circuit Low
One or more of the sensors defective or shorted to chassis ground Correct condition*
P0643
Sensor Power Circuit High
One or more of the sensors defective or shorted to battery power
Correct condition*
P2300
Rear Ignition Coil Primary Circuit Low/SG/ Coil or interconnect harness open or shorted to chassis ground
Correct condition**
Open
P2301
Rear Ignition Coil Primary Circuit High
Coil or interconnect harness shorted to battery power
Correct condition**
P2303
Front Ignition Coil Primary Circuit Low/
Coil or interconnect harness open or shorted to chassis ground
Correct condition**
Open
P2304
Front Ignition Coil Primary Circuit High
Coil or interconnect harness shorted to battery power
Correct condition**
P2531
Ignition Switch Circuit Low
Battery charge condition low or the regulator/rectifier output low
Correct condition*
P2532
Ignition Switch Circuit High
Battery cable connections are loose or the regulator/rectifier output Correct condition*
high
U0155
LCD Gauge to EFI ECM CAN Communica- Gauge CAN circuit or interconnect harness intermittent or has failed Correct condition*
tion Lost
U1000
Vehicle Not Registered or Invalid PIN
An invalid registration PIN has been entered
Enter the correct registraEntered
tion PIN*
U1001
Vehicle Not Registered and Vehicle Limits An invalid registration PIN has been entered
Enter the correct registraEnabled
tion PIN*
FUEL OFF Tilt Sensor Activation Code
Sensor has been activated
Restore the vehicle chassis
to an upright position*

High: A high voltage condition has been detected
Low: A low voltage condition has been detected
Intermittent: An intermittent circuit condition has been detected
Open: An open circuit condition has been detected

148

* After correcting the condition, cycle the key switch On-OffOn
**After correcting the condition, cycle the key switch On-OffOn, start the engine, then cycle the key switch On-OffOn.

OUTPUT VOLTAGE

Tilt Sensor

NOTE: Needle adapters will be required on the
multimeter leads as the following tests are made
with the sensor connected.

! WARNING
Incorrect installation of the tilt sensor could cause sudden loss of engine power which could result in loss of
vehicle control resulting in injury or death.

1. Connect the three-wire plug to the sensor; then
remove the right-side mounting screw securing the
sensor to the rear frame.

CAUTION
Do not drop the tilt sensor as shock can damage the
internal mechanism.

SUPPLY VOLTAGE
1. Disconnect the three-wire connector from the sensor;
then select DC Voltage on the multimeter and connect the red tester lead to the orange wire (C) and the
black tester lead to the black wire (A).

CD707

2. Install the needle adapters to the multimeter leads;
then select DC Voltage on the multimeter.
3. Connect the red tester lead to the blue/brown wire
(B) and the black tester lead to the black/yellow wire
(A); then turn the ignition switch ON and observe the
meter. The meter should read 0.8-3.0 DC volts (700)
or 0.3-1.5 DC volts (500).

CD706A

2. Turn the ignition switch to the ON position. The
multimeter should read battery voltage. If battery
voltage is not indicated, check the 30-amp fuse in the
PDM or the 10-amp ignition fuse, wiring harness, or
the ignition switch.
3. Remove the red tester lead and connect to the pin B.
The multimeter should read approximately 2.5 DC
volts (700) or 0.5 DC volts (500). If the specified
voltage is not indicated, check wire connections at
the ECM or substitute another ECM to verify the
test.

CD705B

4. Tilt the sensor 60° or more to the left and right
observing the meter. The meter should read 4.0-8.0
DC volts (700) or 3.0-7.0 DC volts (500) after
approximately one second in the tilted position. If
the meter readings are not as specified, the tilt sensor
is defective.

CD706B

149

2. Connect the TPS Multi-Analyzer Harness connector
#8 to the TPS; then connect the harness to the TPS
Analyzer Tool.

CD709

NOTE: When replacing the sensor after testing,
make sure the arrow marking is directed up.
FI672

3. On the 500 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 DC Voltage position. With the vehicle
off, the gauge should read 0.66-0.70 and at Wide-Open
Throttle it should read up to approximately 3.88.

CD705A

Throttle Position Sensor
(TPS)
FI673A

NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in this section).

TESTING

4. On the 700 using a multimeter, connect the black tester lead to the black socket (VAR) on the analyzer
and the red tester lead to the white socket (+5V);
then select the DC Voltage position. With the vehicle
off, the gauge should read 0.58-0.62 and at Wide-Open
Throttle it should read up to approximately 3.7.

1. Remove the left-side engine cover; then disconnect
the three-wire TPS connector plug.
NOTE: Prior to testing the TPS, inspect the threewire plug connector on the main harness and the
three-pin plug on the TPS for contamination, broken
pins, and/or corrosion.
NOTE: If the vehicle is in warranty, removing or
adjusting the TPS will void warranty. If the TPS is
tested out of specification, the throttle body must be
replaced. If the vehicle is out of warranty, the TPS
may be adjusted.

150

FI676A

Troubleshooting
Problem: Spark absent or weak
Condition
1.
2.
3.
4.

Ignition coil defective
Spark plug(s) defective
CKP sensor defective
ECM defective

Problem: Spark plug fouled with carbon
Condition
1.
2.
3.
4.
5.

Gasoline incorrect
Air cleaner element dirty
Spark plug(s) incorrect (too cold)
Valve seals cracked - missing
Oil rings worn - broken

Problem: Spark plug electrodes overheat or burn
Condition
1. Spark plug(s) incorrect (too hot)
2. Engine overheats
3. Spark plug(s) loose

Problem: Battery does not charge
Condition
1. Lead wires/connections shorted - loose - open
2. Stator coils shorted - grounded - open
3. Regulator/rectifier shorted

Remedy
1.
2.
3.
4.

Replace ignition coil
Replace plug(s)
Replace CKP sensor
Replace ECM

Remedy
1. Change to correct gasoline
2. Clean element
3. Replace plug(s)
4. Replace seals
5. Replace rings

Remedy
1. Replace plug(s)
2. Service cooling system
3. Tighten plug(s)

Remedy
1. Repair - replace - tighten lead wires
2. Replace stator coils
3. Replace regulator/rectifier

Problem: Battery charges, but charging rate is below the specification
Condition
Remedy
1.
2.
3.
4.

Lead wires shorted - open - loose (at terminals)
Stator coils grounded - open
Regulator/rectifier defective
Cell plates (battery) defective

Problem: Magneto overcharges
Condition
1. Battery short circuited
2. Regulator/rectifier defective
3. Regulator/rectifier poorly grounded

Problem: Charging unstable
Condition
1. Lead wire intermittently shorting
2. Magneto internally shorted
3. Regulator/rectifier defective

Problem: Starter does not engage
Condition
1.
2.
3.
4.
5.
6.

Battery charge low
Switch contacts defective
Starter motor brushes not seating
Starter relay defective
Wiring connections loose - disconnected
Start-in-gear/neutral relay defective

1.
2.
3.
4.

Repair - tighten lead wires
Replace stator coils
Replace regulator/rectifier
Replace battery

Remedy
1. Replace battery
2. Replace regulator/rectifier
3. Clean - tighten ground connection

Remedy
1. Replace lead wire
2. Replace stator coil
3. Replace regulator/rectifier

Remedy
1.
2.
3.
4.
5.
6.

Recharge - replace battery
Replace switch
Replace starter
Replace relay
Connect - tighten - repair connections
Replace relay

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 discharged

Problem: Battery discharges too rapidly
Condition
1.
2.
3.
4.

Charging system (charging operation) not set properly
Cell plates overcharged - damaged
Battery short-circuited
Electrical load too high

Problem: Battery polarity reversed
Condition
1. Battery incorrectly connected

1. Replace battery
2. Charge battery

Remedy
1.
2.
3.
4.

Check AC generator - regulator/rectifier - circuit connections
Replace battery - correct charging system
Replace battery
Reduce load

Remedy
1. Reverse connections - replace battery

151

REMOVING

Drive System

1. Select LOCK on the drive select switch; then disconnect the connector on the actuator harness.
2. Using a T-30 torx wrench, remove the mounting cap
screw from the driveshaft side of the actuator.

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. All gear cases are 4.0:1 ratio.
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assembling
with these screws, start the screws carefully into the
housing; then use the following torque values.
Size
M6 (Torx T-30 Recess)
M8 (Torx T-40 Recess)

New Housing
9 ft-lb
28 ft-lb

Reassembled
Housing
8 ft-lb
23 ft-lb

NOTE: Never reuse a lock nut. Once a lock nut
has been removed, it must be replaced with a new
lock nut.

PR189A

3. Remove the mounting cap screw from above the
actuator on the suspension side.

SPECIAL TOOLS
A number of special tools must be available to the technician when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appropriate tool description.
Description
Backlash Measuring Tool (24-Spline Axle)
Backlash Measuring Tool (27-Spline Axle)
CV Boot Clamp Tool

p/n
0544-010
0544-011
0444-120

Internal Hex Socket
Pinion Gear/Shaft Removal Tool
Gear Case Seal Installer Tool

0444-104

U-Joint Separator Tool

0444-128

0444-127
0444-224

NOTE: Special tools are available from the Arctic
Cat Service Department.

PR190A

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. Remove from the right side.

Front Drive Actuator
NOTE: The actuator is not a serviceable component. If it is defective, it must be replaced.
NOTE: The actuator will operate only when the
ignition switch is in the ON position.

The front drive actuator is located on the right side of the
front drive input housing. With the engine stopped and
the ignition switch in the ON position, a momentary
“whirring” sound can be heard each time the drive select
switch is shifted. If no sound is heard, see the Electrical
System section. If the actuator runs constantly or makes
squealing or grinding sounds, the actuator must be
replaced.

AG928

INSTALLING
1. Lubricate the O-rings on the actuator; then ensure 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.

152

NOTE: Make sure to properly align the differential
lock actuator lever with the hole in the differential
lock plunger.

7. Secure the wiring harness to the frame with a nylon
cable tie.

Front Differential
REMOVING
1. Remove the belly panel; then place the vehicle on
jack stands adjusted high enough to allow working
from the underside of the vehicle.
NOTE: The jack stands should be placed under the
main frame to avoid contact with front suspension
components.
GC002A

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.

! WARNING
Make sure the vehicle is solidly supported on the jack
stands to avoid injury.

2. Remove the drain plug and drain the gear lubricant
into a drain pan; then install the plug and tighten to
45 in.-lb.

GC001

4. Loosen the front cap screw; then tighten the cap
screw on the driveshaft side.

PR022A

3. Remove the front wheels.
4. Place the transmission in park; then turn the ignition
switch to the ON position and select LOCK on the
drive select switch. Turn the ignition switch to the
OFF position.
5. Remove the cotter pin securing the axle nut; then
remove the nut.
NOTE: It is not necessary to remove the brake
hoses from the calipers for this procedure.

6. Remove the two brake calipers. Account for the four
cap screws; then remove the hubs.
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 select switch several times.
153

PR264A

7. Disconnect the front drive actuator connector from
the main harness.

PR222

10. Support the axle to not allow it to drop or hang.

CAUTION
The axle must be supported. If the axle is allowed to
drop or hang, damage to the inner CV joint may occur.

11. Remove the lower shock cap screws. Account for the
lock nuts; then move the shocks and upper A-arm up
and secure them with a strap.

PR191

8. Remove the lower and upper ball joint cap screws
taking care not to strip the threads on the ball joint
shaft; then using a rubber mallet, tap the end of the
axle and free it from the knuckle assembly.
PR200

12. Push the axle shaft toward the differential to release
the “plunge” coupler; then remove the axle from the
differential. Repeat for the opposite side.

PR193

9. Pull the steering knuckle away from the axle.

PR729C

13. Remove the lower differential mounting cap screw.
Account for a lock nut and four washers. Note the
position of the washers for assembling.

154

PR205A

GC015

14. Remove the upper differential mounting cap screw.
Account for a lock nut and two washers.

CD106

CD016

3. Remove the snap rings from the input shaft; then
remove the input shaft from the pinion housing.

15. Free the differential assembly from the frame mountings; then lower the differential through the frame.
Disassembling Input Shaft
NOTE: This procedure can be performed on a rear
gear case.

1. Using a T-40 torx wrench, remove the cap screws
securing the pinion housing.

GC009A

4. Using a seal removal tool, remove the input shaft
seal. Account for a spacer.

GC004A

2. Using a rubber mallet, remove the housing. Account
for a gasket. Remove the fork, collar, and spring.
Note the location of all the components for assembling purposes.

GC010

155

5. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and
remove the bearing.

GC012

GC011

2. Install the input shaft seal making sure it is fully
seated in the edge of the housing.
AF984

GC014
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.

3. Lubricate the input shaft with High-Performance #2
Molybdenum Disulphide Grease packing the boot
ribs and splines; then assemble allowing excess
grease to freely escape. Slight pressure on the boot
will be present during assembly. Secure with new
clamps.
NOTE: Any time drive splines are separated, clean
all splines with parts-cleaning solvent and dry with
compressed air; then lubricate with recommended
grease.

4. Install the input shaft into the pinion housing; then
secure the bearing with a circlip.

156

GC009A

GC015

5. Place the pinion housing with new gasket onto the
differential housing; then secure with existing cap
screws. Tighten to 23 ft-lb.

2. Using a T-40 torx wrench, remove the cap screws
securing the differential cover. Account for and make
note of the ID tag location for assembling purposes.

NOTE: If a new differential housing is being
installed, tighten the cap screws to 28 ft-lb.

GC003

3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring.
KX209

GZ004A

Disassembling Differential Assembly
NOTE: This procedure can be performed on a
rear gear case.

1. Using a T-40 torx wrench, remove the cap screws
securing the pinion housing. Account for the coupler,
fork, and spring (differential only).

KX174

NOTE: If the cover is difficult to remove, pry on
the cover in more than one recessed location.

4. Remove the splined coupler, shifter fork, pin, and
spring of the differential lock assembly and set aside.
Note position of parts for assembling purposes.

157

KX175

5. Remove the left differential bearing flange assembly
and account for a shim. Mark the shim as left-side.

KX181

Disassembling Pinion Gear
1. Remove the internal snap ring securing the pinion
bearing in the housing.

KX177

WC430

2. Using the Pinion Gear/Shaft Removal Tool and a
hammer, remove the pinion gear from the gear case
housing.

KX178

6. Place the differential with the open side down; then
lift the housing off the spider assembly. Account for
shim(s) and mark as right-side.
CC878

3. Secure the pinion gear in a bearing puller; then
remove the pinion bearing using a press. Account for
a collar and a bearing.

KX179

158

CC879

CC884

4. Remove any reusable parts from the gear case housing; then discard the housing and lock collar.

3. Using a propane torch, heat the gear case housing to
approximately 200° F; then install the pinion assembly.

Assembling Pinion Gear
1. Install the bearing onto the pinion shaft. Install the
pinion shaft collar.

4. Install the internal snap ring with the sharp side
directed away from the bearing.

WC429
CC882

Shimming Procedure/Shim Selection
Case-Side Shims (Backlash)
p/n

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

Cover-Side Shims (Ring Gear End-Play)
CC883

2. Place the pinion assembly in a bearing puller; then
install the bearing using a press.

p/n

in.

1402-074

1.3

0.051

1402-075

1.4

0.055

1402-076

1.5

0.059

1402-077

1.6

0.063

1402-078

1.7

0.067

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 differential or rear drive gear case.
159

NOTE: All bearings must be installed in the gear
case and the pinion properly installed before proceeding.

Backlash
NOTE: Always set backlash prior to any other shimming.

1. Install the existing shim or a 0.051-0.055-in. shim on
the gear case side of the ring gear assembly.

GC033A

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.

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.

GC036B

5. Place the appropriate Backlash Measuring 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.

GC036A

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 bearing flange is completely seated in the cover.

GC040

GC032A

160

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 established, the gear case can be assembled.

Assembling Differential Assembly

GC039A

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.

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.

NOTE: Higher backlash settings usually result in
quieter gear operation.

GC031A

GC037A

Ring Gear End-Play
After correcting backlash, ring gear end-play can be
adjusted. To adjust end-play, use the following procedure.
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.

GC020

2. Place the selected (end-play) shim, chamfered side
toward the gear, onto the cover side of the ring gear.

GC036B

GC035

NOTE: The spider and ring gear assembly must be
replaced as a complete unit.

161

3. Assemble the fork and sliding collar into the cover
assembly; then install the left bearing flange/bearing
assembly and seat firmly into the cover.

CF266A

6. Install the shift fork shaft w/spring into the housing
making sure the shaft O-ring is positioned to the
inside.

CC892

7. 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.

CF267A

4. Apply a liberal coat of grease to the O-ring; then
install it on the assembled cover assembly making
sure to seat the O-ring completely down around the
circumference of the bearing flange.

CC893

8. Place the input shaft assembly onto the gear case
housing; then secure with the existing cap screws.
Tighten to 23 ft-lb.
NOTE: If a new housing is being installed, tighten
the cap screws to 28 ft-lb.

CF275A

5. 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
#270). Account for the ID tag. Tighten the cap
screws evenly to 23 ft-lb.
NOTE: Grease can be applied to the O-ring for ease
of assembling.
NOTE: If a new housing is being installed, tighten
the cap screws to 28 ft-lb.

162

CD103

INSTALLING DIFFERENTIAL
1. Place the differential assembly into position in the
frame; then install the top mounting cap screw, two
washers, and lock nut. Do not tighten at this time.
2. Install the lower differential mounting cap screw, washers,
and lock nut. Note the correct location for the washers.

CD110

Removing/Installing Axle Seal
NOTE: This procedure can be performed on a
rear gear case.

1. Remove the seal using a seal removal tool.
PR205A

3. Tighten the nuts to 38 ft-lb.
4. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lubricant into the differential and install the fill plug.
Tighten to 16 ft-lb.
5. Align the scribed match marks on the front input
drive flange and the front drive yoke flange; then
secure with the cap screws tightened to 20 ft-lb.

CC899

NOTE: Prior to installing the seal, apply High-Performance #2 Molybdenum Disulphide grease to the
seal outside diameter.

2. Using Gear Case Seal Installer Tool, evenly press the
seal into the cover bore until properly seated.

PR198A

6. Install the front axles.
7. Install the knuckle assemblies onto the axles and ball
joints; then secure with four cap screws taking care not to
damage the threads when installing. Tighten to 35 ft-lb.

CF278

CAUTION
Make sure the tool is free of nicks or sharp edges or
damage to the seal may occur.

3. Repeat steps 1-2 for the opposite side.
PR201

163

PR193

PR256

8. Secure the lower shock eyelets with cap screws and
lock nuts. Tighten to 20 ft-lb.

12. Install the wheels and tighten in 20 ft-lb increments
to 40 ft-lb (steel wheel) or 80 ft-lb (aluminum
wheel).
13. Remove the vehicle from the support stand.
14. Install the belly panel.

Drive Axles
REMOVING REAR DRIVE AXLE
1. Secure the vehicle on a support stand to elevate the
wheels.
AF897D

9. Install the brake calipers. Secure with new “patchlock” cap screws tightened to 20 ft-lb.

! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.

2. Place the transmission in park; then remove the
wheels.
3. Remove the cotter pins securing the axle nuts; then
remove the nuts.

PR264A

10. Connect the front drive actuator connector to the
main harness; then secure the wires to the frame with
nylon ties.
11. Apply a light coat of multi-purpose grease to the hub
splines; then install the hubs and nuts. Tighten to 200
ft-lb; then install new cotter pins.

164

KX041

4. Slide the hub out of the knuckle and set aside.

PR221

5. Remove the cap screw and lock nut securing the
knuckle to the upper A-arm. Discard the lock nut.

PR729C

REMOVING FRONT DRIVE AXLE
NOTE: For removing a front drive axel, see Front
Differential in this section.

CLEANING AND INSPECTING AXLES
NOTE: Always clean and inspect the drive axle components to determine if any service or replacement is
necessary.

1. Using a clean towel, wipe away any oil or grease
from the axle components.

PR220A

6. While holding the drive axle stationary, pull the top
of the knuckle out and down until it is free of the
drive axle.

CD019

2. Inspect boots for any tears, cracks, or deterioration.
NOTE: If a boot is damaged in any way, it must be
replaced with a boot kit.

INSTALLING REAR DRIVE AXLE
PR218

7. Place a drain pan under the vehicle to contain any oil
leakage; then pushing the axle shaft in, pull the axle
assembly from the gear case.

1. Push the axle shaft into the CV coupler to release the lock
ring; then slide the drive axle into place in the gear case.

PR729C

165

NOTE: To ensure proper axle seating, 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 nut. Tighten the hex nut finger-tight at this time.
4. Tighten the hub hex nut (from step 3) to 200 ft-lb;
then install and spread a new cotter pin making sure
each side of the pin is flush to the hub nut.
CD027

7. Install the wheel and tighten in 20 ft-lb increments to
40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
8. Remove the vehicle from the support stand.
9. Check the front differential lubricant level and add
lubricant as necessary.

CD027

5. Install the wheel. Tighten in 20 ft-lb increments to 40
ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
6. Remove the vehicle from the support stand and
release the parking brake.
INSTALLING FRONT DRIVE AXLE
1. Push the axle shaft into the CV coupler to release the
lock ring; then position the drive axle in the gear case
and steering knuckle; then insert the ball joints into
the steering knuckles. Secure with cap screws tightened to 35 ft-lb.
2. Secure the lower shock eyelet to the A-arm with a
cap screw and a new lock nut. Tighten to 20 ft-lb.
3. Slide the hub w/brake disc into position in the steering knuckle followed by a hex nut. Finger-tighten at
this time.
4. Install the brake caliper on the steering knuckle using
new “patch-lock” cap screws. Tighten to 20 ft-lb.
5. Place the transmission in park; then turn the ignition
switch to the ON position, select LOCK on the drive
select switch. Turn the ignition switch to the OFF
position.
6. Tighten the hex nut (from step 3) to 200 ft-lb; then
install and spread a new cotter pin making sure each
side of the pin is flush to the hub nut.

PR065A

Rear Gear Case
REMOVING
NOTE: Release the cargo box latch and allow the
cargo box to tilt back; then remove the cargo box lift
support by removing the cap screw and nut securing
the lower lift support to the frame. The cargo box will
tilt fully rearward.

1. Drain the lubricant from the rear gear case; then
remove both rear drive axles.
2. Remove the driveline brake caliper; then cut the rearmost propeller shaft boot clamp and slide the boot
forward.
3. Remove the boot clamps on the rear driveline boot.
4. Remove the two cap screws and lock nuts securing
the rear gear case to the frame; then remove the gear
case through the upper left-side of the frame and lift
out the top.

166

PR207

AT THIS POINT
For servicing the input shaft, pinion gear, needle bearing, ring gear, and axle seal, see Front Differential in
this section.

RING GEAR/THRUST BUTTON
Removing

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 shim (clearance too great) or thinner
shim (clearance too small) until correct specification
is reached.

1. Remove the cap screws securing the gear case cover
to the gear case; then remove the ring gear.

REAR DRIVE INPUT SHAFT/
HOUSING

2. Remove the thrust button from the gear case cover
(left-hand threads). Account for a shim.

Removing/Disassembling

Inspecting
1. Inspect the ring gear for excessive wear, missing or
chipped teeth, or discoloration.

1. Remove the cap screws securing the rear drive input
shaft/housing to the rear gear case; then remove the
input housing assembly.

2. Inspect the thrust button for excessive wear or discoloration.
3. Inspect the bearings for discoloration, roughness, or
excessive wear.
Installing/Shimming
NOTE: Ring gear clearance 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).
GZ183

2. Remove the input shaft from the input housing; then
remove the oil seal.

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 0.0020.004 in.

GZ180

167

GZ182A

GZ184

3. Remove the snap ring retaining the input bearing and
using an appropriate bearing driver, press the bearing
from the housing.

2. Using a suitable seal driver, install a new oil seal into
the front of the input housing until the seal is flush
with the housing.

GZ184A

GZ182A

Cleaning and Inspecting

3. Apply grease to the lips of the oil seal; then install
the input shaft into the input bearing and housing.

1. Wash all parts in parts cleaning solvent and dry with
compressed air.

! WARNING
Always wear safety glasses when working with compressed air.

2. Clean all gasket material and sealant from mating
surfaces.
3. Inspect bearings, shafts, and housing for excessive
wear, cracks, or discoloration.
Assembling/Installing
1. Install a new bearing into the input housing and
secure with the snap ring (flat side directed away
from bearing).

GZ179A

4. Using a new gasket, install the assembled rear drive
input shaft/housing onto the rear drive gear case and
secure with the three cap screws. Tighten to 23 ft-lb.

AT THIS POINT
For servicing the input shaft, pinion gear, needle bearing, and axle seal, see Front Differential in this section.

INSTALLING
1. Slide the gear case into position down through the
upper-left side of the frame; then align the driveline
splines to the differential input coupler and engage
the driveshaft and differential.

168

2. Pack the driveline boot with the appropriate grease;
then secure with the boot clamps using CV Boot
Clamp Tool.
3. Secure the differential to the frame with two
through-bolts and secure with lock nuts and flat
washers. Tighten to 38 ft-lb.
4. Install the rear drive axles.
5. Install the brake caliper and tighten the new “patchlock” cap screws to 20 ft-lb.
6. Fill the gear case with the appropriate lubricant.
PR243A

5. Remove the hub assembly.

Hub

6. Remove the four cap screws securing the brake disc.
REMOVING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.
NOTE: Removing or tightening of the hub nuts
requires the axles be locked. To lock the rear axle,
place the transmission in park. To lock the front axle,
turn the ignition switch to ON and select LOCK on the
drive select switch; then place the transmission in
park and turn the ignition switch to OFF.

! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.

2. Remove the cotter pin from the axle.

PR254A

CLEANING AND INSPECTING
1. Clean all hub components.

NOTE: During assembly, new cotter pins should
be installed.

2. Inspect all threads for stripping or damage.
3. Inspect the brake disc (if applicable) for cracks or
warping.
4. Inspect the hub for pits, cracks, loose studs, or spline
wear.
REPLACING WHEEL STUDS
1. Secure the hub in a suitable holding fixture and
remove the brake disc (if applicable).
2. Drive the damaged stud out of the hub; then place the
new stud into the hub and thread on an appropriate
flange nut.

PR257

3. Remove the hub nut securing the hub.
4. Remove the brake caliper (front only).

PR250

169

3. Using a socket and ratchet handle, tighten the nut
until the stud is fully drawn into the hub.

PR258

PR252A

5. Secure the brake calipers to the knuckle with two
new “patch-lock” cap screws tightened to 20 ft-lb.

INSTALLING
1. Secure the brake disc (if applicable) to the hub with
the four cap screws coated with red Loctite #271.
Tighten to 15 ft-lb.
2. Apply grease to the splines in the hub.

PR377B

6. Install the wheel and tighten in 20 ft-lb increments to
40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
7. Remove the vehicle from the support stand.

PR254B

Hydraulic Brake Caliper

3. Install the hub assembly onto the axle; then place the
transmission in park.

! WARNING
Arctic Cat recommends only authorized Arctic Cat ROV
dealers perform hydraulic brake service. Failure to
properly repair brake systems can result in loss of control causing severe injury or death.

REMOVING/DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.

! WARNING
PR221

4. Secure the hub assembly with the nut. Tighten to 200
ft-lb; then secure with a new cotter pin.
NOTE: If the cotter pin cannot be inserted due to
misalignment of the hole in the axle and the slots in
the nut, tighten the nut until properly aligned.

Make sure the vehicle 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.

2. Drain the brake fluid from the caliper, hose, and
master cylinder through the bleed screw by pumping
the brake pedal.
170

PR235

CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the vehicle and do not reuse brake
fluid.

PR238

5. Remove the caliper holder from the caliper and discard the O-ring.

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 significantly 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.

PR239B

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: The O-ring is used for shipping purposes
and provides no function in operation.

NOTE: If brake pads are to be returned to service,
do not allow brake fluid to contaminate them.

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.

PR237A

PR713A

171

PR715

! WARNING
Make sure to hold the towel firmly in place or the piston
could be ejected from the housing causing injury.

PR717A

2. Press the piston into the caliper housing using hand
pressure only. Completely seat the piston; then wipe
off any excessive brake fluid.

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. Discard 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 the Periodic Maintenance - Hydraulic Brake System.

PR711A

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.

CAUTION
Make sure the seals are properly in place and did not
twist or roll during installation.

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
PR715

172

4. Install the caliper onto the caliper holder making sure
the caliper and holder are correctly oriented.

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.

NOTE: It is very important to apply silicone
grease to the O-rings and caliper bores prior to
assembly.

8. Fill the reservoir; then bleed the brake system (see
Periodic Maintenance - Hydraulic Brake System).

! 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.

9. Install the wheel. Tighten in 20 ft-lb increments to 40
ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
10. Remove the vehicle from the support stand and verify brake operation.
MASTER CYLINDER 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.

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.

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 until the
reservoir is empty.

AF637D
PR238

2. Remove the cotter pin and pivot pin from the yoke;
then remove two cap screws and flange nuts securing
the master cylinder assembly to the frame.

PR239

6. Place the brake caliper assembly into position and
secure with new “patch-lock” cap screws. Tighten
the caliper to 20 ft-lb.

PR338

173

3. Remove the cap screws securing the driveshaft
flange to the output flange; then remove the driveshaft.

PR336

3. Remove the oil bolt securing the banjo-fittings to the
master cylinder; then remove the master cylinder.
Discard the three crush washers.

CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the vehicle.

Inspecting

HDX157

4. Install U-Joint Separator Tool on the universal joint
fixed yoke; then remove the bearing cup retainers.
5. Using a suitable socket and ratchet handle, rotate the
jackscrew to push the bearing cup out of the yoke;
then remove the tool and the bearing cup.

1. Inspect the master cylinder push rod and clevis for
wear, bending, or elongation of clevis holes.
2. Inspect the push rod boot for tears or deterioration.
3. Inspect the reservoir for cracks and leakage.
4. Inspect the brake hose for cracks and deterioration
and the condition of the banjo-fittings.
Installing
1. Place the master cylinder into position; then using
three new crush washers, secure the two banjo-fittings to the master cylinder. Tighten to 20 ft-lb.
2. Secure the master cylinder assembly to the frame
with two cap screws and two flange nuts. Tighten to
25 ft-lb.
3. Install the pivot pin and secure with a new cotter pin.
4. Fill the master cylinder and bleed the brake system
(see Hydraulic Brake System in the Periodic Maintenance section).

PR359

6. Install the separator tool on the opposite side of the
yoke to push the second bearing cup from the yoke;
then remove the tool and separate the universal joint.
7. Secure the separator tool in a vise and repeat steps 46 to remove the bearing cups from the movable yoke.

Universal Joints
REMOVING
NOTE: The universal joints can be accessed by
removing the belly panel. To remove the belly
panel, see the Steering/Frame/Controls section.

1. Support the vehicle on suitable jack stands elevated
high enough to allow working from the underside of
the vehicle.
2. To aid in installing, match mark drive-line components prior to removing.

174

PR375

INSPECTING
1. Inspect the yoke bores for damage or signs of bearing cup looseness. If bearing cups are loose, the yoke
must be replaced.

PR367B

2. Check that yoke legs are parallel.

PR368

2. Secure U-Joint Separator Tool in a vise; then place
the yoke, joint, and bearing cup into position and
press the cup into the yoke.

PR367A

3. Check splines and flanges for excessive wear, thread
damage, or warpage.

PR374

3. Install the retainer in the bearing cup; then remove
the yoke from the separator tool.
NOTE: Repeat steps 2-3 for the opposite-side bearing cup.

4. Remove the separator tool from the vise and install
the universal joint, bearing cups, and movable yoke
into the fixed yoke using the same procedure as steps
2-3 except the vise cannot be used.

PR367C

INSTALLING
1. Remove the bearing cups from the universal joint;
then insert the joint into the yoke and install one
bearing cup on the joint.

CAUTION
Care must be taken when installing bearing cups that
the needle bearings stay in place or severe damage to
the universal joint will occur.

PR355

5. Check that the universal joint can be flexed freely
without binding; then apply multi-purpose grease to
the splines and install the driveshaft noting the match
marks made prior to removing.

175

Troubleshooting Drive
System
Problem: Power not transmitted from engine to wheels
Condition
1. Rear axle shaft serration worn - broken

Remedy
1. Replace shaft

Problem: Power not transmitted from engine to either front wheel
Condition
Remedy
1.
2.
3.
4.
5.
6.
7.

Secondary drive - driven gear teeth broken
Propeller shaft serration worn - broken
Coupling damaged
Coupling joint serration worn - damaged
Front drive - driven bevel gears broken - damaged
Front differential gears/pinions broken - damaged
Front drive actuator not operating

1.
2.
3.
4.
5.
6.
7.

Replace gear(s)
Replace shaft
Replace coupling
Replace joint
Replace gear(s)
Replace gears - pinions
Replace fuse - drive select switch - front drive actuator

Troubleshooting Brake
System
Problem: Braking poor
Condition
1. Pad worn
2. Brake fluid leaking
3. Master cylinder/brake cylinder seal worn

Problem: Brake pedal travel excessive
Condition
1. Brake fluid low
2. Piston seal - cup worn

Problem: Brake fluid leaking
Condition
1. Connection fittings loose
2. Hose cracked
3. Piston seal worn

Problem: Brake pedal spongy
Condition
1. Air trapped in hydraulic system
2. Brake fluid low

176

Remedy
1. Replace pads
2. Repair - replace hydraulic system
3. Replace seal(s)

Remedy
1. Add fluid to proper level
2. Replace seal - cup

Remedy
1. Tighten fittings
2. Replace hose
3. Replace seal

Remedy
1. Bleed hydraulic system
2. Add brake fluid and bleed hydraulic brake system

3. Using a suitable spring compression stand, compress
the shock absorber spring, remove the retainer, and
remove the spring.

Suspension

! WARNING
The following suspension system components should be
inspected periodically to ensure proper operation.
A. Shock absorber rods bent, pitted, or damaged.

Shock absorber springs are under high compression
loads. Do not attempt to remove springs without an adequate spring compressor. Sever injury could result.

B. Rubber damper cracked, broken, or missing.
C. Shock absorber body damaged, punctured, or
leaking.
D. Shock absorber eyelets broken, bent, or cracked.
E. Shock absorber eyelet bushings worn, deteriorated, cracked, or missing.
F. Shock absorber spring broken or sagging.
G. Sway bar mountings tight and bushings secure.
SPECIAL TOOL
CF341

A special tool must be available to the technician when
performing service procedures in this section. Refer to
the current Special Tools Catalog for the appropriate tool
description.
Description
Spring Removal Tool

p/n
0644-057

NOTE: Special tools are available from the Arctic
Cat Service Department.

Front Shock Absorbers
REMOVING
1. Secure the vehicle on a support stand to elevate the
wheels and to release load on the suspension.

! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.

2. Remove the two cap screws and nuts securing each
front shock absorber to the frame and upper A-arm.
Account for bushings and sleeves from each.

CLEANING AND INSPECTING
1. Clean all shock absorber components in parts-cleaning solvent.
2. Inspect each shock rod for nicks, pits, rust, bends, and
oily residue.
3. Inspect all springs, spring retainers, shock rods,
sleeves, bushings, shock bodies, and eyelets for
cracks, leaks, and bends.
INSTALLING
1. Place the shock absorber spring over the shock
absorber, compress the spring, and install the retainer.
2. Place bushings and sleeves (where appropriate) into
shock eyelet; then install shocks with two cap screws
and nuts.
3. Tighten the front shock absorber cap screws to 35 ftlb.
4. Remove the vehicle from the support stand.

Rear Shock Absorbers
The rear shock absorbers are Fox Air shocks with springover feature incorporating fixed pre-load coil springs
over variable pressure air shocks.
REMOVING
1. Secure the vehicle on a support stand to elevate the
wheels and to release load on the suspension.

! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.
AF605D

177

2. Remove the upper and lower mounting cap screws
and lock nuts. Discard the lock nuts.

4. Remove the air chamber from the bottom of the
shock body.

3. Using a suitable spring compressor, compress the
spring and retainer ring from the lower shock body.
4. Carefully release the spring pressure and remove the
spring. Account for the spring retainer.
DISASSEMBLING

! WARNING
Always wear latex or rubber gloves when servicing a
shock absorber with shock oil.

1. Remove the valve cap; then bleed the air from the air
chamber.
FS144

5. Using a pick, remove the air valve ball from the
nitrogen bladder.

FS141

2. While holding the end cap; unscrew the air chamber.
FS145A

6. Using an Allen-wrench, loosen the nitrogen bladder
½ turn.

FS142

3. Drain the oil from the air chamber.
FS146

7. Using Inflation Needle (p/n 0744-020), remove all
the nitrogen from the shock.

FS143

178

11. Remove the shock rod/piston assembly from the
shock body.

FS147

8. Using a 5/64-in. Allen-wrench, remove the set screw
from the bearing cap.

FS151

12. Drain the oil from the shock body into a suitable container.
13. Using an appropriate floating piston removal tool,
remove the floating piston.

FS148

9. Using a magnet held against the Allen-wrench,
remove the bleed ball.

FS152

NOTE: For ease in removing the piston, use the
inflation needle to help vent the shock body.

FS149

10. Using Spanner Wrench (p/n 0644-453), loosen the
bearing cap.

FS153

14. Clean and inspect all components.
ASSEMBLING/CHARGING
1. Lubricate the O-ring and wiper on the floating piston
with shock oil.

FS150

179

FS154

FS157

2. Carefully install the floating piston into the shock
body until it is below the threads.

5. Lubricate the O-ring on the underside of the end cap
with shock oil.

FS155

FS158

3. Using an appropriate location tool, install the floating piston to a depth of 7.0 in. while using the inflation needle to vent the shock body.

6. Lower the shock rod into the shock body until the
piston is submerged in oil.

FS156

7. While keeping the shock rod fully extended, thread
the bearing cap into position.

FS159

4. Using Fox Racing Shock Oil, fill the shock body to
the bottom of the threads; then, allow to sit 1-2 minutes to ensure no air is in the oil.

FS160

180

8. Using Spanner Wrench, tighten the bearing cap.

10. Charge the shock with nitrogen to 200 psi.

FS161

NOTE: When tightening the bearing cap, note air
and excess oil being bled from the hole in the cap.

FS164

11. Using a 3/16-in. Allen-wrench, tighten the
nitrogen bladder.

FS165
FS150A

9. Install the bleed ball and set screw into the bearing
cap.

12. Install the air valve ball by gently tapping it with a
plastic mallet.

FS166
FS162

13. Test the shock for proper operation.
14. Using compressed air, blow all oil from the holes in
the bearing cap.

FS163

181

18. Thread the air chamber into the end cap until handtight.

FS167

15. Lubricate the seal on the air chamber with Fox Float
Fluid.

FS171

NOTE: Prior to installing the air chamber, make sure
the end cap O-ring is properly positioned in the
chamber.

19. Invert the shock and secure by the end cap to assure
the air chamber is tight.

FS168

16. Slide the air chamber onto the shock body.

FS172

20. Using a hand pump, inflate the air chamber to the
appropriate pressure.
Payload
0-250 lb
250-500 lb
500-750 lb
750-1000 lb

Pressure
15 psi
60 psi (min)
90 psi (min)
150 psi

FS169

17. Add 1 cc of Fox Float Fluid into the chamber.

FS173

! WARNING
FS170

182

Do not exceed 150 psi in the shock.

21. Install the valve cap.

CD007
FS174

22. Install the spring using an appropriate spring compressor and secure with the retaining ring.
INSTALLING
1. Install the shock absorber (valve stem at the top) and
secure with the cap screws. Tighten new lock nuts to
35 ft-lb.
2. Lower the vehicle to the ground.

5. Remove the hub assembly.
6. Remove the cotter pin and slotted nut securing the tie
rod end to the knuckle; then remove the tie rod end
from the knuckle.
7. Remove the cap screws securing the ball joints to the
knuckle.

CAUTION
Support the knuckle when removing the cap screws or
damage to the threads will occur.

Front A-Arms
REMOVING
1. Secure the vehicle on a support stand to elevate the
front wheels; then remove the wheels.

! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.

2. Remove the cotter pin from the nut. Discard the cotter
pin.

PR193

8. Tap the ball joints out of the knuckle; then remove the
knuckle.
9. Remove the lower shock absorber eyelet from the
upper A-arm.

PR257

3. Remove the nut securing the hub.
4. Remove the brake caliper. Account for two cap
screws.

AF626D

10. Remove the cap screws securing the A-arms to the
frame.

183

AF610D

AF616D

11. Remove the snap ring from the ball joint; then remove
the ball joint from the A-arm.

2. Install the A-arm assemblies into the frame mounts
and secure with the cap screws. Only finger-tighten at
this time.

AF616D

CLEANING AND INSPECTING
1. Clean all A-arm components in parts-cleaning solvent.

AF610D

3. Route the brake hose through the upper A-arm shock
absorber mount.

2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes.
3. Inspect the A-arm for bends, cracks, and worn bushings.
4. Inspect the ball joint mounting holes for cracks or
damage.
5. Inspect the frame mounts for signs of damage, wear,
or weldment damage.
INSTALLING
1. Apply Loctite Primer “T” to the A-arm socket; then
apply green Loctite #609 to the entire outside diameter of the ball joint. Install the ball joint into the A-arm
and secure with the snap ring.

AF627D

4. Secure the lower eyelet of the shock absorber to the
upper A-arm. Tighten nut to 20 ft-lb.
5. Secure the A-arm assemblies to the frame mounts
(from step 2). Tighten the cap screws to 35 ft-lb.
6. Install the knuckle assembly onto the ball joints and
secure with cap screws. Tighten to 35 ft-lb.

184

AF628D

PR377B

7. Install the tie rod end and secure with the nut (coated
with red Loctite #271). Tighten to 30 ft-lb; then install
a new cotter pin and spread the pin to secure the nut.

11. Secure the hub nut (from step 9) to the shaft/axle.
Tighten to 200 ft-lb.

NOTE: During assembly, new cotter pins should
be installed.

12. Install a new cotter pin and spread the pin to secure the
nut.
NOTE: If the cotter pin cannot be inserted due to
misalignment of the hole in the axle and the slots
in the nut, tighten the nut until properly aligned.

AF618D

8. Apply grease to the hub and drive axle splines; then
install the hub assembly onto the drive axle.

PR260

13. Install the wheel and tighten in 20 ft-lb increments to
40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
14. Remove the vehicle from the support stand.

Rear A-Arms
REMOVING
1. Secure the vehicle on a support stand to elevate the
wheels.
PR290A

9. Secure the hub assembly with the nut. Tighten only
until snug.
10. Secure the brake caliper holder to the knuckle with
two new “patch-lock” cap screws. Tighten to 20 ft-lb.

! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.

2. Place the transmission in park.
3. Remove the wheel.
4. Remove the cotter pin securing the hex nut; then
remove the hex nut.

185

5. Remove the cap screws and lock nut securing the
shock absorber to the frame and lower A-arm; then
remove the shock absorber.

4. Apply grease on the drive axle splines; then install the
hub assembly onto the drive axle.

6. Remove the cap screws securing the boot guard to the
lower A-arm.

PR221

5. Secure the hub assembly with the nut. Tighten to 200
ft-lb.
AF934

6. Install a new cotter pin and spread the pin to secure the
nut.

8. Remove the cap screws and lock nuts securing the
knuckle to the A-arms. Discard the lock nuts.

NOTE: If the cotter pin cannot be inserted due to
misalignment of the hole in the axle and the slots
in the nut, tighten the nut until properly aligned.

7. Slide the axle out of the knuckle and set aside.

PR220A

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 Aarms to the frame; then remove the A-arms.
CLEANING AND INSPECTING

PR196

7. Secure the shock absorber to the frame with a cap
screw and new lock nut. Tighten to 35 ft-lb.
8. Secure the shock absorber to the lower A-arm with a
cap screw and new lock nut. Tighten to 35 ft-lb.

1. Clean all A-arm components in parts-cleaning solvent.

9. Secure the boot guard to the lower A-arm with the two
cap screws. Tighten securely.

2. Inspect the A-arm for bends, cracks, and worn bushings.

10. Install the wheel and tighten in 20 ft-lb increments to
40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).

3. Inspect the frame mounts for signs of damage, wear,
or weldment damage.

11. Remove the vehicle from the support stand.

INSTALLING
1. Install the A-arm assemblies into the frame mounts
and secure with the cap screws and new lock nuts.
Finger-tighten only at this time.
2. Slide the knuckle onto the drive axle and into position
on the A-arms; then secure the knuckle to the A-arms
with cap screws and new lock nuts. Tighten to 35 ft-lb.
3. Tighten the hardware securing the A-arms to the
frame mounts (from step 1) to 33 ft-lb.
186

Wheels and Tires

2. Remove the nuts securing the wheels; then remove the
wheels.
CLEANING AND INSPECTING
1. Clean the wheels and hubs with parts-cleaning solvent.

TIRE SIZE

! WARNING
Use only Arctic Cat approved tires when replacing tires.
Failure to do so could result in unstable vehicle operation.

This vehicle is equipped with low-pressure tubeless tires
of the size and type listed in the General Information section. Do not under any circumstances substitute tires of a
different type or size.

! WARNING
Always use the size and type of tires specified. Always
maintain proper tire inflation pressure.

! 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 vehicle and could
cause excessive drive train damage not covered by warranty.

TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 1.41 kg/
cm² (20 psi).
REMOVING
1. Secure the vehicle on a support stand to elevate the
wheels.

! WARNING

2. Clean the tires with soap and water.
3. Inspect each wheel for cracks, dents, or bends.
4. Inspect each tire for cuts, wear, missing lugs, and
leaks.
INSTALLING
1. Install each wheel on its hub and secure with the existing hardware.
2. Tighten in 20 ft-lb increments to 40 ft-lb (steel
wheel) or 80 ft-lb (aluminum wheel).
CHECKING/INFLATING
1. Using an air pressure gauge, measure the air pressure
in each tire. Adjust the air pressure as necessary to
meet the recommended inflation pressure.
2. Inspect the tires for damage, wear, or punctures.

! WARNING
Do not operate the vehicle if tire damage exists.

NOTE: If repair is needed, follow the instructions
found on the tire repair kit or remove the wheel
and have it repaired professionally.
NOTE: Be sure all tires are the specified size and
have identical tread pattern.

Make sure the vehicle is solidly supported on the support stand to avoid injury.

187

Troubleshooting
Problem: Suspension too soft
Condition
1.
2.
3.
4.

Spring preload incorrect
Spring(s) weak
Shock absorber damaged
Rear shock absorbers too soft

Problem: Suspension too stiff
Condition
1. Spring preload incorrect
2. A-arm-related bushings worn

Problem: Suspension noisy
Condition
1. Cap screws (suspension system) loose
2. A-arm-related bushings worn

Problem: Vehicle pulling or steering erratic
Condition
1. Vehicle steering is erratic on dry, level surface
2. Vehicle pulls left or right on dry, level surface

188

Remedy
1.
2.
3.
4.

Adjust preload
Replace spring(s)
Replace shock absorber
Check and adjust air pressure in shocks

Remedy
1. Adjust preload
2. Replace bushing

Remedy
1. Tighten cap screws
2. Replace bushings

Remedy
1. Check front wheel alignment and adjust if necessary (see the
Steering/Frame/Controls - Checking/Adjusting Front Wheel
Alignment)
2. Check air pressure in tires and adjust to specifications

Printed in U.S.A.

Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-861

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