2014 Prowler HDX Service

User Manual: Manual

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FRONT COVER
FOREWORD
Table of Contents
BACK COVER

PROWLER HDX

[ROV]

SERVICE MANUAL

2014

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 com-

pleted 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 fol-

low the directive because it deals with the possibility of serious personal injury or even death. A CAUTION identi-

fies 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 wor-

thy of particular attention. The symbol  AT THIS POINT directs the technician to certain and specific proce-

dures 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.

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

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

Specifications subject to change without notice.

MISCELLANY

Tire Size (front)

(rear)

26 x 10R-14

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)

(700)

3.3 L (3.5 U.S. qt) - Overhaul

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

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

(One inch below plug threads)

SAE Approved 80W-90 Hyp-

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)

ELECTRICAL SYSTEM

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Cap 5000 ohms

Ignition Coil Resistance (primary)

(secondary)

Less than 5.0 ohms - 500

Less than 1 ohm - 700

12k-19k ohms - 500

1.8M ohms - 700

Ignition Coil Primary Voltage Battery Voltage

Stator Coil Resistance (CKP Sensor)

(AC generator)

150-250 ohms

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

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)

(2nd)

11.6 mm

10.1 mm

Bore x Stroke 89.0 x 71.2 mm

Cylinder Trueness (max) 0.01 mm

Piston Ring End Gap - Installed (min) 0.15 mm

Piston Ring to Groove Clearance (max) (1st/

2nd)

0.06 mm

Piston Ring Groove Width (1st)

(2nd)

(oil)

1.01-1.03 mm

1.21-1.23 mm

2.01-2.03 mm

Piston Ring Thickness (1st)

(2nd)

0.97-.99 mm

1.17-1.19 mm

Piston Pin Bore (max) 20.008 mm

Piston Pin (min) 19.994 mm

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)

(1st/2nd)

0.03 mm

Piston Ring Groove Width (1st/2nd)

(oil)

1.202-1.204 mm

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)

(exhaust)

35.0 mm

30.5 mm

Valve/Tappet Clearance (intake)

(cold engine) (exhaust)

0.10 mm

0.17 mm

Valve Guide/Stem (intake)

Clearance (max) (exhaust)

0.10 mm

0.30 mm

Valve Guide/Valve Stem Deflection

(Wobble Method) (Max)

0.35 mm

Valve Face Radial Runout (max) 0.15 mm

Valve Guide Inside Diameter 5.000-5.012 mm

Valve Stem Outside Diameter (intake)

(exhaust)

4.975-4.990 mm

4.955-4.970 mm

Valve Stem Runout (max) 0.10 mm

Valve Face/Seat Width (min)(intake/exhaust) 0.99 mm

Valve Seat Angle (intake/exhaust) 45°

Valve Spring Free Length (min) 44.73 mm

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

VALVES AND GUIDES (700)

Valve Face Diameter (intake)

(exhaust)

31.6 mm

27.9 mm

Valve/Tappet Clearance (intake)

(cold engine) (exhaust)

0.1016 mm

0.1524 mm

Valve Guide/Stem Clearance 0.013 mm

Valve Guide/Valve Stem Deflection

(Wobble Method) (Max)

0.35 mm

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)

(exhaust)

2.25 mm

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)

Torque Specifications

NOTE: Torque specifications have the following tol-

erances:

* w/Blue Loctite #243 ** w/Red Loctite #271

*** w/Green Loctite #270 **** w/“Patch-Lock”

CRANKSHAFT (500)

Connecting Rod (small end) (max) 20.021 mm

Connecting Rod (big end side-to-side)

(max) 0.7 mm

Connecting Rod (big end width) 21.95-22.00 mm

Connecting Rod (small end deflection)

(max) 3.0 mm

Crankshaft (web-to-web) 60.9 mm

Crankshaft Runout (max) 0.03 mm

CRANKSHAFT 700)

Connecting Rod (small end inside (max)

(diameter)

23.021 mm

Connecting Rod (big end side-to-side)(min) 0.6 mm

Connecting Rod @ 150 mm (max)

(small end deflection)

0.3 mm

Crankshaft (web-to-web) (min) 71 mm

Crankshaft Runout (max) 0.03 mm

CAMSHAFT AND CYLINDER HEAD (500)

Cam Lobe Height (min) (intake)

(exhaust)

34.71 mm

34.48 mm

Camshaft Journal Holder(right & center)

Inside Diameter (left)

22.01-22.04 mm

17.51-17.54 mm

Camshaft Journal Outside(right & center)

Diameter (left)

17.466-17.480 mm

21.966- 21.980 mm

Camshaft Runout (max) 0.03 mm

Rocker Arm Inside Diameter 10.00-10.15 mm

Rocker Arm Shaft Outside Diameter 9.972-9.987 mm

Cylinder Head/Cover Distortion (max) 0.05 mm

Camshaft Journal/Cylinder Head

Clearance (max)

0.074 mm

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

Torque (ft-lb) Tolerance

0-15 ±20%

16-39 ±15%

40+ ±10%

EXHAUST COMPONENTS

Part Part Bolted To Torque

ft-lb N-m

Exhaust Pipe Cylinder Head 20 27

Spark Arrester Muffler 50

in.-lb

O2 Sensor Exhaust Pipe 19 26

BRAKE COMPONENTS

Brake Disc**** Hub 15 20

Brake Hose Caliper 20 27

Brake Hose Master Cylinder 20 27

Master Cylinder Frame 25 34

Caliper**** Knuckle 20 27

Rear Driveline **** Rear Differential 12 16

ELECTRICAL COMPONENTS

Coil* Frame 811

DRIVE TRAIN COMPONENTS

Part Part Bolted To Torque

ft-lb N-m

Rear Differential/Gear Case Frame 38 48

Drive Coupler (Front) Front Drive Flange 40 54

Front Engine Mounting

Bracket

Frame 45 61

Rear Engine Mounting BracketFrame 45 61

Engine Mounting Through-BoltFrame 40 54

Front Differential Frame/Differential Bracket 38 52

Rear Output Flange Rear Driven Flange 40 54

Input Shaft Assembly Gear Case Housing 23 31

Pinion Housing Differential Housing 23 31

Secondary Shaft Bearing

Housing

Crankcase 28 38

Rear Cradle Frame 25 34

Driveshaft (Front/Rear) Engine 20 27

Shift Cable Bracket Engine 811

Front Input Drive Flange Front Drive Yoke Flange 20 27

Driveline Rear Drive Input Flange 20 27

Differential Housing Cover*** Differential Housing 23 31

Thrust Button** Gear Case Cover 811

Drive Bevel Gear Nut*** Shaft 87 118

Lock Collar Differential Housing 125 170

Hub Nut Front/Rear Shaft/Axle (min) 200 272

Oil Drain Plug Front Differential - Rear

Drive 45

in.-lb

Oil Fill Plug Front Differential - Rear

Drive

16 22

Oil Drain Plug Engine 16 22

Wheel Hub 80 108

STEERING COMPONENTS

Steering Wheel** Steering Wheel Shaft 25 34

Steering Wheel Shaft*** Intermediate Shaft (Upper) 31 42

Intermediate Shaft (Lower)*** Steering Pinion Shaft 36 49

Rack and Pinion Assembly Frame 35 48

Tie Rod Rack 37 50

Tie Rod End** Knuckle 30 41

Jam Nut Tie Rod End 10 14

Steering Shaft Coupler EPS Input Shaft 11 15

EPS Cradle Bracket Frame 20 27

EPS Assembly Frame 35 48

EPS Assembly Rack Coupler 11 15

Intermediate Shaft Coupler Intermediate Shaft 31 42

Steering Shaft Housing (6

mm)

Frame 811

Steering Shaft Housing (8

mm)

Frame 20 27

CHASSIS/ROPS ASSEMBLY

Shift Axle Support Frame 48

in.-lb

Front/Rear ROPS Tube Arm Rest/Steering Support 35 48

Top ROPS Support Front/Rear ROPS Tubes 35 48

Rear ROPS Tube Lower ROPS Support 35 48

Shift Cable Shift Arm Stud 834

Shift Cable Mounting/Adjuster Shift Cable 20 27

Cargo Box Hinge Cargo Box Frame 20 27

Side Panel/Spacer Cargo Box Frame 25 34

Tilt Pivot Bushing Cargo Box Frame 15 20

Latch Striker Cargo Box Liner 60

in.-lb

SUSPENSION COMPONENTS (Front)

Part Part Bolted To Torque

ft-lb N-m

A-Arm Frame 35 48

Knuckle Ball Joint 35 48

Shock Absorber Frame/Upper A-Arm 35 48

Shock Absorber Lower A-Arm 20 27

Knuckle A-Arm 35 48

SUSPENSION COMPONENTS (Rear)

Sway Bar Bracket Frame 35 48

A-Arm Frame 35 48

Shock Absorber Lower A-Arm 35 48

Shock Absorber Frame 35 48

Knuckle A-Arm 35 48

ENGINE/TRANSMISSION (500)

Clutch Shoe** Crankshaft 147 199

Clutch Cover/Housing Assembly Crankcase 811

Left-Side Cover Crankcase 811

Crankcase Half (6 mm) Crankcase Half 10 13.5

Crankcase Half (8 mm) Crankcase Half 21 28

Cylinder Nut Crankcase Half 811

Cylinder Head (Cap Screw) Crankcase 28 38

Cylinder Head Nut Cylinder 20 27

Cylinder Head Cover Cylinder Head 811

Oil Pump Drive Gear** Crankshaft 63 86

Driven Pulley Nut** Driveshaft 147 199

Ground Cable Engine 811

Magneto Rotor Nut Crankshaft 107 146

Cam Sprocket** Camshaft 11 15

Valve Adjuster Jam Nut Valve Adjuster 79.5

Starter Motor Crankcase 811

Oil Fitting Engine 811

Starter One-Way Clutch Flywheel 26 35

Oil Pump* Crankcase 811

Movable Drive Face Nut** Clutch Shaft 147 199

Output Shaft Flange Nut Output Shaft 59 80

Cam Chain Tensioner Guide Cylinder 11 15

Valve Inspection Cover Cylinder Head Cover 811

Cam Chain Tensioner Cylinder 10 13.5

Magneto Cover Crankcase 811

Rear Driveline Output Drive Flange 20 27

Water Pump Cover/Housing Magneto Cover 811

Water Pump Drive Gear Crankshaft 28 38

ENGINE/TRANSMISSION (700)

Clutch Shoe** Crankshaft 221 300

Clutch Cover/Housing Assem-

bly

Crankcase 811

Crankcase Half (6 mm) Crankcase Half 10 14

Crankcase Half (8 mm) Crankcase Half 20 27

Cylinder Head (Cap Screw) Crankcase 40 54

Cylinder Head Nut (6 mm) Cylinder 811

Cylinder Head Nut (8 mm) Cylinder 18 24

Valve Cover Cylinder Head 8.5 11.5

Driven Pulley Nut Driveshaft 80 109

Movable Drive Face Nut** Driveshaft 165 224

Ground Wire Engine 811

Magneto Cover Crankcase 811

Tappet Cover Valve Cover 912

Crankshaft Spacer Crankshaft 28 38

Oil Pump Cover** Crankcase 811

Oil Pump Drive Gear** Crank Balancer Shaft 62 84

Output Shaft Flange Nut** Output Shaft 62 84

One-Way Clutch** Rotor/Flywheel 26 35

Outer Magneto Cover Side Cover 811

Magneto Rotor Nut** Crankshaft 105 143

Cam Sprocket** Camshaft 11 15

Speed Sensor Housing Crankcase 811

V-Belt Cover Crankcase 811

Output Yoke Nut** Secondary Driven Output

Shaft 74 100

Output Shaft Flange Yoke/

Nut**

Output Shaft 59 80

Secondary Shaft Bearing

Housing

Crankcase Half 28 38

Stator Coil* Magneto Cover 13 18

Intake Manifold Boot Clamp Intake Boot 30 in.-

3.4

Ground Wire Engine 811

Torque Conversions

(ft-lb/N-m)

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.

RECOMMENDED ENGINE/

TRANSMISSION OIL

The recommended oil to use is Arctic Cat ACX All

Weather synthetic engine oil, which has been specifi-

cally 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.

FILLING GAS TANK

Since gasoline expands as its temperature rises, the gas

tank must be filled to its specified capacity only. Expan-

sion room must be maintained in the tank particularly if

the tank is filled with cold gasoline and then moved to a

warm area

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

11.4 26 35.4 51 69.4 76 103.4

22.7 27 36.7 52 70.7 77 104.7

34.1 28 38.1 53 72.1 78 106.1

45.4 29 39.4 54 73.4 79 107.4

56.8 30 40.8 55 74.8 80 108.8

68.2 31 42.2 56 76.2 81 110.2

79.5 32 43.5 57 77.5 82 111.5

810.9 33 44.9 58 78.9 83 112.9

912.2 34 46.2 59 80.2 84 114.2

10 13.6 35 47.6 60 81.6 85 115.6

11 15 36 49 61 83 86 117

12 16.3 37 50.3 62 84.3 87 118.3

13 17.7 38 51.7 63 85.7 88 119.7

14 19 39 53 64 87 89 121

15 20.4 40 54.4 65 88.4 90 122.4

16 21.8 41 55.8 66 89.8 91 123.8

17 23.1 42 57.1 67 91.1 92 125.1

18 24.5 43 58.5 68 92.5 93 126.5

19 25.8 44 59.8 69 93.8 94 127.8

20 27.2 45 61.2 70 95.2 95 129.2

21 28.6 46 62.6 71 96.6 96 130.6

22 29.9 47 63.9 72 97.9 97 131.9

23 31.3 48 65.3 73 99.3 98 133.3

24 32.6 49 66.6 74 100.6 99 134.6

25 34 50 68 75 102 100 136

CAUTION

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

line additives should be used.

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These oils

can adversely affect clutch operation. Also, not recom-

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

tor-based oils.

CAUTION

Any lubricant used in place of the recommended lubri-

cant could cause serious front differential/rear drive

damage.

! WARNING

Always fill the gas tank in a well-ventilated area. Never

add fuel to the gas tank near any open flames or with

the engine running. DO NOT SMOKE while filling the

gas tank.

Tighten the gas tank cap securely after filling the 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

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 vehi-

cle. 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, rap-

idly inject the preserver into the air filter opening for

a period of 10 to 20 seconds; then stop the engine.

Install the air filter and housing cover.

4. Plug the exhaust hole in the exhaust system with a

clean cloth.

5. Apply light oil to the plungers of the shock absorb-

ers.

6. Tighten all nuts, bolts, cap screws, and screws. Make

sure rivets holding components together are tight.

Replace all loose rivets. Care must be taken that all

calibrated nuts, cap screws, and bolts are tightened to

specifications.

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

pipe in the radiator neck with properly mixed cool-

ant.

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

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

clean, dry area.

9. Store the vehicle indoors in a level position.

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.

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 mak-

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

tightened to specifications.

9. Check tire pressure. Inflate to recommended pres-

sure as necessary.

10. Make sure the steering moves freely and does not

bind.

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

! WARNING

Do not overflow gasoline when filling the gas tank. A

fire hazard could materialize. Always allow the engine to

cool before filling the gas tank.

! WARNING

Do not over-fill the gas tank.

CAUTION

Prior to storing the vehicle, it must be properly serviced

to prevent rusting and component deterioration.

CAUTION

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

area before starting the engine.

CAUTION

Avoid storing outside in direct sunlight and avoid using

a plastic cover as moisture will collect on the vehicle

causing rusting.

CAUTION

The ignition switch must be in the OFF position prior to

installing the battery or damage may occur to the igni-

tion system.

CAUTION

Connect the positive battery cable first; then the nega-

tive.

Periodic Maintenance

This section has been organized into sub-sections which show

common maintenance procedures for the Arctic Cat ROV.

SPECIAL TOOLS

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

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Department.

Periodic Maintenance

Chart

A = Adjust I = Inspect C = Clean R = Replace T = Tighten L = Lubricate

* 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.

Description p/n

Compression Tester Kit 0444-213

Oil Filter Wrench 0644-389

Timing Light 0644-296

Valve Clearance Adjuster 0444-255

Item

Initial Service

After Break-In

(First Month or

100 Miles)

Every

Day

Every Month or

Every 100 Miles

Every 3

Months or

Every 300

Miles

Every 6

Months or

Every 500

Miles

Every Year or

Every 1500

Miles

Needed

Battery II C

Fuses IR

Air Filter I I* R

Valve/Tappet Clearance IIA

Engine Compression I

Spark Plug I I I R (4000 Mi or

18 Mo)

Muffler/Spark Arrester CR

Gas Hoses II R (2 Yrs)

Throttle Cable Ends/Accelerator Pedal

Pivot II C-L A-R

Engine-Transmission Oil Level I A

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

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

Tires/Air Pressure II R

Steering Components II I R

V-Belt IlR

Suspension (Ball joint boots, drive axle

boots front and rear, tie rods, differential

and rear drive bellows)

II R

Nuts/Bolts/Cap Screws TT A

Ignition Timing I

Headlight/Taillight-Brakelight II R

Switches II R

Shift Lever IA-L

Gauges/Indicators II R

Frame/Welds II l

Electrical Connections lC

Complete Brake System

(Hydraulic) II

Brake Pads II* R

Brake Fluid IIR (2 Yrs)

Brake Hoses IIR (4 Yrs)

Coolant/Cooling System II R (2 Yrs)

Wheel Lug Nuts TT

Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the

components using the following list as reference.

A. Accelerator Pedal Pivot/Cable Ends

B. Brake Pedal Pivot

C. Shift Cable

Air Filter

1. Raise the cargo box; then remove any dust and debris

from around the filter housing.

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

cover.

HDX050A

3. Fill a wash pan larger than the element with a non-

flammable cleaning solvent; then dip the element in

the solvent and wash it.

NOTE: Foam Filter Cleaner and Foam Filter Oil are

available from Arctic Cat.

4. Dry the element.

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

oil and work the element. Reattach the filter to the

filter screen.

NOTE: Carefully squeeze excess oil from the ele-

ment.

6. Clean any dirt or debris from inside the filter hous-

ing. Be sure no dirt enters the throttle body.

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

CHECKING AND CLEANING DRAINS

1. Inspect the “duck-bill” drain beneath the main hous-

ing 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.

Valve/Tappet Clearance

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

lowing procedure.

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



NOTE: The seat, seat back, seat base, and spark

plug must be removed for this procedure.

1. Remove the spark plug and timing inspection plug; then

remove the tappet covers (for more detailed informa-

tion, see the Engine/Transmission section - Servicing

Top-Side Components).

2. Rotate the crankshaft to the TDC position on the

compression stroke.

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

screws must not have pressure on them.

Feeler Gauge Procedure

Using a feeler gauge, check each valve/tappet clearance.

If clearance is not within specifications, loosen the jam

nut and rotate the tappet adjuster screw until the clear-

ance is within specifications. Tighten each jam nut

securely after completing the adjustment.

CC007D

CAUTION

Failure to inspect the air filter frequently if the vehicle is

used in dusty, wet, or muddy conditions can damage

the engine.

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.

CAUTION

The feeler gauge must be positioned at the same angle

as the valve and valve adjuster for an accurate measure-

ment of clearance. Failure to measure the valve clear-

ance accurately could cause valve component damage.

VALVE/TAPPET CLEARANCE

Intake 0.1016 mm (0.004 in.)

Exhaust 0.1524 mm (0.006 in.)

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.

D. While holding the valve adjuster handle in place,

rotate the valve adjuster dial counterclockwise

until proper valve/tappet clearance is attained.

NOTE: Refer to the specifications in Feeler

Gauge Procedure sub-section for the proper valve/

tappet clearance.

NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by

0.05 mm (0.002 in.) per mark.

E. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

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

tion plug.

4. Place the two tappet covers with O-rings into posi-

tion. Tighten the cap screws to 9 ft-lb.

Testing Engine

Compression

To test engine compression, use the following procedure.

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.

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

lead to the plug and ground the plug on the cylinder

head well away from the spark plug hole.

4. Attach the Compression Tester Kit.

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).

6. If compression is abnormally low, inspect the

following items.

A. Starter cranks engine over.

B. Gauge is functioning properly.

C. Throttle in the full-open position.

D. Valve/tappet clearance correct.

E. Engine warmed up.

F. Intake obstructed.



NOTE: To service top-side components, see the

Engine/Transmission section.

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

spark plug hole, reattach the gauge, and retest com-

pression.

8. If compression is now evident, service the piston

rings (see the appropriate Engine/Transmission - Top

Side Components).

Spark Plug

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.

ATV-0051

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

! WARNING

Always wear safety glasses when using compressed

air.

PSI Hot (WOT) PSI Cold (WOT)

125-145 100-140

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.

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

Clean the spark arrester using the following procedure.

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.

PR498

PR499

2. Using a suitable brush, clean the carbon deposits

from the screen taking care not to damage the screen.

NOTE: If the screen or gasket is damaged in any

way, it must be replaced.

3. Install the spark arrester assembly and gasket and

secure with the cap screws. Tighten the cap screws to

48 in.-lb.

Engine/Transmission Oil -

Filter

OIL - FILTER

Change the engine oil and oil filter at the scheduled inter-

vals. 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.

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 fil-

ter.

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.

5. Install the engine drain plug and tighten to 16 ft-lb. Pour

the specified amount of the recommended oil in the filler

hole.

HDX042A

! WARNING

Wait until the muffler cools to avoid burns.

500

HDX042A

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.

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.

GZ461A

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.

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

level with the bottom threads.

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.

HDX255

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.

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These oils

can adversely affect clutch operation. Also, not recom-

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

tor-based oils.

CAUTION

Do not over-fill the engine with oil. Always make sure

that the oil level is not above the upper mark.

700

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/Taillight-

Brakelight

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.

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.

3. Install the new bulb into the socket and rotate it com-

pletely 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.

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 hori-

zontal 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.

0740-647

7. Using the adjuster knob, adjust each headlight until cor-

rect aim is obtained.

CD714A

! WARNING

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

burns may result.

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.

HDX251

HDX254

3. Loosen nuts (A) and (B) and adjust the cable housing

to align the shift 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 selec-

tion 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 sys-

tem, 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 res-

ervoir is not above the MIN, add DOT 4 brake fluid.

PR095

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.

700

500

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.

HDX236A

AF637D

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 main-

tain a sufficient amount of fluid in the reservoir will

result in air in the system.

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.

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses for cracks or

other damage. If found, the brake hoses must be replaced.

CHECKING/REPLACING PADS

The clearance between the brake pads and brake discs is

adjusted automatically as the brake pads wear. The only

maintenance that is required is replacement of the brake

pads when they show excessive wear. Check the thick-

ness of each of the brake pads as follows.

1. Remove the wheel corresponding to the brake being

checked.

2. Measure the thickness of each brake pad.

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.

4. To replace the brake pads, use the following proce-

dure.

A. Remove the cap screws securing the caliper

holder to the knuckle; then remove the pads from

the caliper.

REAR 500

REAR 700

FRONT

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.

PR237

B. Install the new brake pads.

C. Secure the caliper holder to the knuckle with new

“patch-lock” cap screws. Tighten to 20 ft-lb.

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

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.

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.

3. Repeat procedure 20 times until brake pads are bur-

nished.

Checking/Replacing V-

Belt

REMOVING

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

2. Remove the floor (see Steering/Frame/Controls);

then remove the gas tank (see Fuel/Lubrication/

Cooling).

3. Remove the screws securing the right-side storage com-

partment; 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.

CD963

CD966A

! 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.

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 V-

belt.

PR476A

GZ085

INSTALLING

1. Place the V-belt into position on the driven pulley and

over the front shaft.

GZ085

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

ward.

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

GZ485A

NOTE: At this point, remove the cap screw from

the driven pulley face.

3. Rotate the V-belt and driven pulley/clutch until the V-

belt 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.

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.

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 full-

right capability.

C. Steering sector mounting bolts tight.

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

E. Tie rods not bent or cracked.

F. Knuckles not worn, cracked, or damaged.

G. Cotter pins not damaged or missing.

H. Steering wheel tilt locks securely.

The frame and welds should be checked periodically for

damage, bends, cracks, deterioration, broken compo-

nents, and missing components.

Electronic Power

Steering (EPS)

REMOVING

NOTE: Certain models are equipped with elec-

tronic power steering. Thoroughly troubleshoot

the EPS system prior to replacing the EPS assem-

bly (see the Electrical System section) as there are

several possible external causes for system fail-

ure.

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.

PR759A

3. Remove the cap screw securing the intermediate

shaft yoke to the EPS assembly input shaft.

PR760A

4. Remove the steering wheel; then remove the steering

wheel boot support.

PR762A

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 assem-

bly.

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.

PR764A

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.

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).

PR766A

2. Rotate the EPS shaft to align the index (flattened)

spline with the slot in the rack coupler.

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.

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.

PR764B

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.

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 over-

tighten.

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

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.

PR780

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.

PR784

4. While holding the rack shaft with a wrench, tighten

the tie rod joint to 37 ft-lb using an appropriate crow-

foot.

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.

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.

PR785A

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.

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.

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.

PR785

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 assem-

bly; 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.

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

1. Remove the steering wheel cover; then match mark

the steering shaft and steering wheel.

NOTE: Any time steering components are disas-

sembled, 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 pad-

ding, or broken spokes.

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.

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.

HDX131A

Upper Steering Shaft

REMOVING

1. Remove the dashboard (see Dashboard in this sec-

tion).

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.

PR764A

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.

NOTE: Any time steering components are disas-

sembled, 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 hous-

ing for cracking or excessive wear.

INSTALLING

1. Install the steering shaft housing with steering shaft con-

necting 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.

PR764B

3. Install the cap screw in the intermediate shaft coupler

and tighten to 31 ft-lb.

PR765A

Intermediate Steering

Shaft Assembly

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 exces-

sive 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.

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.

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.

AT THIS POINT

Before beginning this procedure, the upper steering shaft

must be removed.

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.

PR765A

5. Install the dash and connect the two electrical con-

nectors. 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.

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.

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.

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.

PR289

CLEANING AND INSPECTING

1. Clean all knuckle components.

2. Inspect the bearing for pits, scoring, rusting, or pre-

mature 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.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

PR292A

PR289

2. Install the knuckle to the upper and lower ball joints

and secure with the two cap screws. Tighten to 35 ft-

lb.

PR202

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.

NOTE: During assembling, new cotter pins

should be installed.

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

PR290A

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

CD009

6. Secure the hub assembly with the nut. Tighten to 200

ft-lb.

PR256

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

shown.

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.

PR377B

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.

PR709

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 sec-

tion).

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.

HDX166A

HDX168A

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.

HDX168

2. Secure the shift cable end to the shift arm stud with

the cap screw and nut. Tighten to 8 ft-lb.

Shift Cable

REMOVING

1. Remove the dashboard (see Dashboard in this sec-

tion).

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.

HDX166A

HDX178A

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

4. Remove the center floorboard and remove all nylon

ties securing the cable housing to the frame; then

remove the 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.

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.

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).

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 steer-

ing wheel boot support to the steering support assem-

bly. Remove the 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.

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.

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

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.

HDX131A

Checking/Adjusting Front

Wheel Alignment

NOTE: All measurements and adjustments must

be made with the vehicle unloaded.

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).

PR087A

To adjust the wheel alignment, use the following proce-

dure.

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.

HDX098B

PR085A

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.

PR086

Front Bumper Assembly

REMOVING

Remove four cap screws and nuts. Account for four lock

washers and eight flat washers.

PR327A

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 posi-

tioned. Tighten securely.

CAUTION

Always use a wrench to hold the tie rod ends when loos-

ening or tightening the jam nuts or damage to the boots

could occur.

Hood

REMOVING

1. Open the hood; then disconnect the four headlight

connectors and remove two 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.

PR332A

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.

PR332

3. Connect the four headlight connectors; then secure

the wires with two new nylon ties.

PR332B

Fenders

REMOVING

Remove three torx-head screws securing each fender to

the frame. Account for a stiffener bracket on the front

fenders.

PR311A

INSTALLING

Place the appropriate fender into position and secure with

existing hardware.

Floor

REMOVING

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

2. Remove the self-tapping screws securing the side

foot restraints.

3. Remove the center floorboard.

HDX132A

4. While pulling forward on the upper-rear of the floor,

lift the rear part of the floor above the seat locating

stud.

PR163

NOTE: To aid in removing, insert a small wood

block to hold in position.

PR164

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.

CLEANING AND INSPECTING

1. Clean the floor with soap and water.

2. Inspect the floor for cracks or holes.

INSTALLING

1. Place the front of the floor into position in the vehi-

cle first; then lower the rear and push past the seat

locating studs.

2. Secure the floor with the cap screws and self-tap-

pings screws.

3. Install the center floorboard; then install the seat

base, seat back, and seat.

Dashboard

REMOVING

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.

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 steer-

ing shaft and shift lever assemblies.

INSTALLING

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.

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 Loc-

tite #271 to the steering shaft; then tighten the

steering wheel nut to 25 ft-lb and install the lock

clip.

4. Install the steering wheel cover.

5. Check shifter/shift cable adjustment (see Periodic

Maintenance - Shift Lever).

Belly Panel

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

REMOVING MUFFLER

1. Remove the two exhaust springs at the muffler/

exhaust pipe juncture.

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.

NOTE: For additional details on cleaning the muf-

fler/spark arrester, see the Periodic Maintenance.

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.

Cargo Box

REMOVING

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.

HDX257

2. Loosen but do not remove the four shoulder cap

screws securing the pivot housings to the cargo box.

PR335

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.

3. Inspect the welds of the cargo box frame for cracking

or bending.

4. Inspect the cargo box gate latches for smooth opera-

tion.

INSTALLING

1. With the help of an assistant or an adequate lift, set

the cargo box into position on the frame; then posi-

tion 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 crack-

ing.

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 Remedy

1. Front wheel alignment incorrect

2. Steering shaft binding

3. Tire inflation pressure incorrect

4. Tie rod ends seizing

5. U-joints seized

1. Adjust alignment

2. Lubricate/replace steering shaft

3. Adjust pressure

4. Replace tie rod ends

5. Replace U-joints

Problem: Steering oscillation

Condition Remedy

1. Tires inflated unequally

2. Wheel(s) bent

3. Wheel hub studs loose - missing

4. Wheel hub bearing worn - damaged

5. Tie rod ends worn - loose

6. Tires defective - incorrect

7. A-arm bushings damaged

8. Bolts - nuts (frame) loose

1. Adjust pressure

2. Replace wheel(s)

3. Tighten - replace wheel studs

4. Replace bearing

5. Replace - tighten tie rod ends

6. Replace tires

7. Replace bushings

8. Tighten bolts - nuts

Problem: Steering pulling to one side

Condition Remedy

1. Tires inflated unequally

2. Front wheel alignment incorrect

3. Wheel hub bearings worn - broken

4. Frame distorted

5. Shock absorber defective

1. Adjust pressure

2. Adjust alignment

3. Replace bearings

4. Repair - replace frame

5. Replace shock absorber

Problem: Steering impaired

Condition Remedy

1. Tire pressure too high

2. Steering linkage worn

3. Cap screws (suspension system) loose

1. Adjust pressure

2. Replace linkage

3. Tighten cap screws

Problem: Tire wear rapid or uneven

Condition Remedy

1. Wheel hub bearings worn - loose

2. Front wheel alignment incorrect

1. Replace bearings

2. Adjust alignment

Problem: Steering noise

Condition Remedy

1. Caps screws - nuts loose

2. Wheel hub bearings broken - damaged

3. Lubrication inadequate

1. Tighten cap screws - nuts

2. Replace bearings

3. Lubricate appropriate components

Problem: Rear wheel oscillation

Condition Remedy

1. Rear wheel hub bearings worn - loose

2. Tires defective - incorrect

3. Wheel rim distorted

4. Wheel hub cap screws loose

5. Rear suspension arm-related bushing worn

6. Rear shock absorber damaged

7. Rear suspension arm nut loose

1. Replace bearings

2. Replace tires

3. Replace rim

4. Tighten cap screws

5. Replace bushing

6. Replace shock absorber

7. Tighten nut

Engine/Transmission

This section has been organized into sub-sections which

show a progression for the complete servicing of the Arc-

tic Cat ROV engine/transmission.

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

mission must be removed from the frame. To service top-

side, left-side, and right-side components, the engine/

transmission does not have to be removed from the

frame.

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

kets, lock nuts, and seals and lubricating all internal

components when servicing the engine/ transmis-

sion.

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.

SPECIAL TOOLS

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

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Department.

Description p/n

Seal Protector Tool 0444-252

Crankcase Separator/Crankshaft Remover 0444-152

Magneto Rotor Remover Set 0444-254

Piston Pin Puller 0644-328

Secondary Drive Gear Holder 0444-253

Spanner Wrench 0444-240

Surface Plate 0644-016

V Blocks 0644-535

Troubleshooting

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

Condition Remedy

1. Valve clearance out of adjustment

2. Valve guides worn

3. Valves mistimed

4. Piston rings worn - broken

5. Cylinder bore worn

6. Starter motor cranks too slowly - does not turn

1. Adjust clearance

2. Replace guides

3. Retime engine

4. Replace rings

5. Replace cylinder

6. See Electrical System

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

Condition Remedy

1. Spark plug fouled

2. Spark plug wet

3. Magneto defective

4. ECM defective

5. Ignition coil defective

6. High-tension lead open - shorted

1. Clean - replace plug

2. Clean - dry plug

3. Replace stator coil

4. Replace ECM

5. Replace ignition coil

6. Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)

Condition Remedy

1. Gas tank vent hose obstructed

2. Fuel hose obstructed

3. Fuel screens obstructed

4. Fuel pump defective

1. Clean vent hose

2. Clean - replace hose

3. Clean - replace inlet screen

4. Replace fuel pump

Problem: Engine stalls easily

Condition Remedy

1. Spark plug fouled

2. Magneto defective

3. ECM defective

4. Fuel injector obstructed

5. Valve clearance out of adjustment

1. Clean - replace plug

2. Replace stator coil

3. Replace ECM

4. Replace fuel injector

5. Adjust clearance

Problem: Engine noisy (Excessive valve chatter)

Condition Remedy

1. Valve clearance excessive

2. Valve spring(s) weak - broken

3. Rocker arm - rocker arm shaft worn

4. Camshaft worn

1. Adjust clearance

2. Replace spring(s)

3. Replace arm - shaft

4. Replace camshaft

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

Condition Remedy

1. Piston - cylinder worn

2. Combustion chamber carbon buildup

3. Piston pin - piston pin bore worn

4. Piston rings - ring groove(s) worn

1. Replace cylinder - service piston

2. Clean cylinder head and piston

3. Replace - service pin - bore

4. 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. Main bearing worn - burned

2. Lower rod-end bearing worn - burned

3. Connecting rod side clearance too large

4. Centrifugal clutch loose

5. Rotor/flywheel loose

1. Replace bearing

2. Replace crankshaft assembly

3. Replace crankshaft assembly

4. Tighten - replace clutch

5. Tighten - replace flywheel - crankshaft

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

Condition Remedy

1. Gears worn - chipped

2. Splines worn

3. Primary gears worn - chipped

4. Bearings worn

5. Bushing worn

1. Replace gears

2. Replace shaft(s) - gears

3. Replace gears

4. Replace bearings

5. Replace bushing

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

Condition Remedy

1. Drive - driven bevel gears damaged - worn

2. Backlash excessive

3. Tooth contact improper

4. Bearing damaged

5. Gears worn - chipped

6. Splines worn

7. Final driven shaft thrust clearance too large

1. Replace gears

2. Adjust backlash

3. Adjust contact

4. Replace bearing

5. Replace gears

6. Replace shaft(s) - gears

7. Replace thrust washer(s)

Problem: Engine idles poorly

Condition Remedy

1. Valve clearance out of adjustment

2. Valve seating poor

3. Valve guides defective

4. Rocker arms - arm shaft worn

5. Magneto defective

6. ECM defective

7. Spark plug fouled - gap too wide

8. Ignition coil defective

9. Fuel injector obstructed

1. Adjust clearance

2. Replace - service seats - valves

3. Replace guides

4. Replace arms - shafts

5. Replace stator coil

6. Replace ECM

7. Adjust gap - replace plug

8. Replace ignition coil

9. Replace fuel injector

Problem: Engine runs poorly at high speed

Condition Remedy

1. High RPM “cut out” against RPM limiter

2. Valve springs weak

3. Valve timing out of adjustment

4. Cams - rocker arms worn

5. Spark plug gap too narrow

6. Ignition coil defective

7. Air cleaner element obstructed

8. Fuel hose obstructed

1. Shift into higher gear - decrease speed

2. Replace springs

3. Adjust timing

4. Replace cams - arms

5. Adjust gap

6. Replace ignition oil

7. Clean element

8. Clean - prime hose

Problem: Exhaust smoke dirty or heavy

Condition Remedy

1. Engine oil overfilled - contaminated

2. Piston rings - cylinder worn

3. Valve guides worn

4. Cylinder wall scored - scuffed

5. Valve stems worn

6. Stem seals defective

1. Drain excess oil - change oil

2. Replace cylinder - service rings

3. Replace guides

4. Replace cylinder

5. Replace valves

6. Replace seals

Problem: Engine lacks power

Condition Remedy

1. Valve clearance incorrect

2. Valve springs weak

3. Valve timing out of adjustment

4. Piston ring(s) - cylinder worn

5. Valve seating poor

6. Spark plug fouled

7. Rocker arms - shafts worn

8. Spark plug gap incorrect

9. Fuel injector obstructed

10. Air cleaner element obstructed

11. Engine oil overfilled - contaminated

12. Intake manifold leaking air

13. Cam chain worn

1. Adjust clearance

2. Replace springs

3. Time camshaft

4. Replace cylinder - service rings

5. Repair seats

6. Clean - replace plug

7. Replace arms - shafts

8. Adjust gap - replace plug

9. Replace fuel injector

10. Clean element

11. Drain excess oil - change oil

12. Tighten - replace manifold

13. Replace cam chain - sprockets

Problem: Engine overheats

Condition Remedy

1. Carbon deposit (piston crown) excessive

2. Oil low

3. Octane low - gasoline poor

4. Oil pump defective

5. Oil circuit obstructed

6. Intake manifold leaking air

7. Coolant level low

8. Fan malfunctioning

9. Fan relay malfunctioning

10. Thermostat stuck - closed

11. Radiator hoses - cap damaged - obstructed

1. Clean piston

2. Add oil

3. Drain - replace gasoline

4. Replace pump

5. Clean circuit

6. Tighten - replace manifold

7. Fill - examine system for leaks

8. Check fan fuse/fan relay - replace fan

9. Replace fan relay

10. Replace thermostat

11. 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.

Support the vehicle on a suitable lift or jack stands allow-

ing room to perform work from the underside.

NOTE: Locate the jack stands to allow removing

of the center belly panel.

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 pur-

poses, from the right side disconnect the MAP

sensor connector (A), fuel injector connector (B),

ISC connector (C), and TPS connector (D).

HDX136A

5. Wrap the gasline hose connector with a shop cloth;

then remove the gasline hose connector from the

fuel rail.

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.

HDX031A

7. Remove four sheet metal screws securing the air fil-

ter mounting bracket to the frame; then loosen the air

inlet boot clamp and disconnect the IAT sensor con-

nector and remove the air filter assembly.

HDX148A

HDX144A

AT THIS POINT

If the technician’s objective is to service/replace right-

side cover oil seals, front output joint oil seal, rear out-

put 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.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stands to avoid injury.

! WARNING

Gasoline may be under pressure. Place an absorbant

towel around the connector to absorb any gasoline

spray when disconnected.

8. Loosen the clamp securing the throttle body to the

intake manifold boot; then remove the throttle body

and set aside.

9. From the left side, disconnect the ECT sensor con-

nector, speed sensor connector, and spark plug cap.

HDX135A

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.

HDX254

HDX251

NOTE: On the 500, shifting the transmission into

park will aid in accessing the shift arm cap screw.

11. Disconnect the starter cable from the starter; then

remove the cap screw securing the engine/harness

ground wires to the engine case.

HDX149A

12. Remove the CVT inlet and exhaust ducts from the

V-belt housing.

HDX146A

500

700

HDX147A

13. Remove the forward heat shield from the exhaust

pipe; then remove the cap screws securing the

exhaust pipe to the cylinder head.

HDX152A

HDX154

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

HDX247

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.

HDX153A

16. Remove the cap screws securing the driveshafts to

the front and rear engine flanges; then disconnect

the upper and lower coolant hoses.

HDX158A

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.

HDX157A

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

Top-Side Components

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which

need to be addressed and to service only those

components. The technician should use discretion

and sound judgment.

NOTE: The engine/transmission does not have to

removed from the frame for this procedure.

Removing Top-Side

Components

A. Cylinder Head Cover/

Rocker Arms

B. Cylinder Head/Camshaft

NOTE: Remove the spark plug, timing inspection

plug, and outer magneto cover; then using an

appropriate wrench, rotate the crankshaft to top-

dead-center of the compression stroke.

NOTE: Arctic Cat recommends the use of new

gaskets, lock nuts, and seals and lubricating all

internal components when servicing the engine/

transmission.

1. Remove the cap screws securing the two tappet cov-

ers. Remove the two tappet covers. Account for the

O-rings.

FI603

NOTE: Keep the mounting hardware with the cov-

ers for assembly purposes.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

2. Remove the cylinder head cover cap screws. Note

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

remove the cylinder head cover. Note the orientation

of the cylinder head plug and remove it. Note the

location of the two alignment pins.

FI606A

MD1354A

3. Remove the cap screw from the tension adjuster;

then using a flat-blade screwdriver, relax the cam

chain tension by rotating the adjuster screw clock-

wise until it locks.

FI607A

FI608

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

securing the sprocket to the camshaft.

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.

FI613

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

ring down into the crankcase.

MD1131

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 cyl-

inder head. Account for an alignment pin.

NOTE: Loop the chain over the cylinder and

secure it to keep it from falling into the crankcase.

FI620

FI617A

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.

FI616

FI617

FI618A

FI619A

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

ers. Note that the two cap screws on the right side of

the cylinder head nearest the cam sprocket are longer

than the two cap screws on the left (spark plug) side.

CD211

9. Remove the cylinder head from the cylinder, remove

the gasket, and account for two alignment pins.

FI623A

10. Remove the cam chain guide.

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.

FI622A

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.

FI624A

13. Using an awl, remove one piston-pin circlip. Take

care not to drop it into the crankcase.

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.

AT THIS POINT

To service valves and cylinder head, see Servicing Top-

Side Components sub-section.

AT THIS POINT

To inspect cam chain guide, see Servicing Top-Side

Components sub-section.

AT THIS POINT

To service cylinder, see Servicing Top-Side Compo-

nents sub-section.

CAUTION

When removing the cylinder, be sure to support the pis-

ton to prevent damage to the crankcase and piston.

MD1219

NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install a con-

necting rod holder.

Servicing Top-Side

Components

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 sol-

vent.

2. Place the cylinder head cover on the Surface Plate

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

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

ure eight motion. Inspect the sealing surface for any

indication of high spots. A high spot can be noted by

a bright metallic finish. Correct any high spots

before assembly by continuing to move the cylinder

head cover in a figure eight motion until a uniform

bright metallic finish is attained.

CC130D

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.

CC132D

2. Remove the valve seal and the lower remaining spring

seat. Discard the valve seal.

CAUTION

Do not allow the connecting rod to go down inside the

crankcase. If the rod is down inside the crankcase and

the crankshaft is rotated, severe damage will result.

AT THIS POINT

To service piston, see Servicing Top-Side Components

sub-section.

AT THIS POINT

To service center crankcase components only, proceed

to Removing Left-Side Components.

CAUTION

Do not remove an excessive amount of the sealing sur-

face or damage to the camshaft will result. Always

check camshaft clearance when resurfacing the cylin-

der head cover.

CAUTION

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

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

the sealing surface may result.

CC134D

CC136D

NOTE: The valve seals must be replaced.

3. Remove the valve springs; then invert the cylinder

head and remove the valves.

Measuring Valve Stem Runout

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

check the valve stem runout using a dial indicator.

ATV-1082

2. Maximum runout must not exceed specifications.

Measuring Valve Stem Outside

Diameter

1. Using a micrometer, measure the valve stem outside

diameter.

2. Acceptable diameter ranges must be within specifi-

cations.

Measuring Valve Face/Seat Width

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

FI367

2. Acceptable width must be at or above specifications.

Measuring Valve Face Radial Runout

1. Mount a dial indicator on the surface plate; then

place the valve stem on a set of V blocks.

2. Position the dial indicator contact point on the out-

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

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.

Measuring Valve Guide

(Inside Diameter)

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

guide bore; then remove the gauge and measure it

with a micrometer.

2. Acceptable inside diameter range must be within

specifications.

3. If a valve guide is out of tolerance, the cylinder head

must be replaced.

Servicing Valves/Valve Guides/Valve

Seats

If valves, valve guides, or valve seats require servicing

or replacement, Arctic Cat recommends that the compo-

nents be taken to a qualified machine shop for servicing.

Measuring Rocker Arm

(Inside Diameter)

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

the rocker arm.

2. Acceptable inside diameter range must be within

specifications.

Measuring Rocker Arm Shaft

(Outside Diameter)

1. Using a micrometer, measure the outside diameter of

the rocker arm shaft.

2. Acceptable outside diameter range must be within

specifications.

Installing Valves

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

then place a lower spring seat and valve guide seal

over each valve guide.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve springs with the painted end of the

spring facing away from the cylinder head.



NOTE: If the paint is not visible, install the ends of the

springs with the closest wound coils toward the head.

ATV-1011A

4. Place a spring retainer over the valve springs; then

using the valve spring compressor, compress the

valve springs and install the valve keepers.

CC132D

PISTON ASSEMBLY

NOTE: Whenever a piston, rings, or pin are out of

tolerance, they must be replaced.

Cleaning/Inspecting Piston

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the top of the piston.

2. Inspect the piston for cracks in the piston pin, boss,

top, and skirt areas.

3. Inspect the piston for seizure marks or scuffing. If

piston is scored or galled, replace it with a new one.

4. Inspect the perimeter of each piston for signs of

“blowby” indicated by dark discoloration. “Blowby”

is caused by worn piston rings, excessive carbon in

ring grooves, or an out-of-round cylinder.

Removing Piston Rings

1. Starting with the top ring, slide one end of the ring

out of the ring-groove.

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.

CAUTION

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

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

to grind the valves or severe engine damage may occur.

Cleaning/Inspecting Piston Ring

Grooves

1. Take an old piston ring and snap it into two pieces;

then grind the end of the old ring to a 45° angle and

to a sharp edge.

2. Using the sharpened ring as a tool, clean carbon from

the ring grooves. Be sure to position the ring with its

tapered side up.

Measuring Piston-Ring End Gap

(Installed)

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

inder. Use the piston to position each ring squarely in

the cylinder.

2. Using a feeler gauge, measure each piston-ring end

gap. Acceptable ring end gap must not exceed speci-

fications.

CC995

Measuring Piston Pin, Connecting

Rod Small End, and Piston-Pin Bore

1. Measure the piston pin outside diameter at each end

and in the center. If measurement does not meet

specifications, the piston pin must be replaced.

ATV-1070

2. Inspect and measure the connecting rod small end

inside diameter. If the measurement exceeds specifi-

cations, 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.

ATV-1069

Measuring Piston Skirt/

Cylinder Clearance

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

CC127D

2. Measure the corresponding piston diameter at a point

8 mm (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.

CAUTION

Improper cleaning of the ring grooves by the use of the

wrong type of ring groove cleaner will result in severe

damage to the piston.

ATV-1085B

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

on the top surface of each ring faces the dome of the

piston. Rotate the rings until the ring end gaps are on

directly opposite sides of the piston according to the

illustration.

NOTE: The chrome (silver) ring should be

installed in the top position.

MD1343A

CYLINDER/CYLINDER HEAD

ASSEMBLY

NOTE: If the cylinder/cylinder head assembly

cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the combustion chamber

being careful not to nick, scrape, or damage the com-

bustion chamber or the sealing surface.

2. Inspect the spark plug hole for any damaged threads.

Repair damaged threads using a “heli-coil” insert.

3. Place the cylinder head on the surface plate covered

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

pressure, move the cylinder head in a figure eight

motion. Inspect the sealing surface for any indication

of high spots. A high spot can be noted by a bright

metallic finish. Correct any high spots before assem-

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

ure eight motion until a uniform bright metallic

finish is attained.

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion

chamber.

2. Lay a straightedge across the cylinder head; then

using a feeler gauge, check the distortion factor

between the head and the straightedge.

3. Maximum distortion must not exceed specifications.

CC141D

Cleaning/Inspecting Cylinder

1. Wash the cylinder in parts-cleaning solvent.

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

warpage, and corrosion. If marks are found, repair

the surface using a cylinder hone (see Honing Cylin-

der in this sub-section).

3. Place the cylinder on the surface plate covered with

#400 grit wet-or-dry sandpaper. Using light pressure,

move the cylinder in a figure eight motion. Inspect

the sealing surface for any indication of high spots.

A high spot can be noted by a bright metallic finish.

Correct any high spots before assembly by continu-

ing to move the cylinder in a figure eight motion

until a uniform bright metallic finish is attained.

CAUTION

Incorrect installation of the piston rings will result in

engine damage.

CAUTION

The cylinder head studs must be removed for this pro-

cedure.

CAUTION

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

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

the sealing surface may result.

CAUTION

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

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

the sealing surface may result.

CC129D

Inspecting Cam Chain Guide

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

chips.

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

Honing Cylinder

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

gauge, measure the cylinder bore diameter in three

locations from top to bottom and again from top to

bottom at 90° from the first measurements for a total

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

ness) is the difference between the highest and low-

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

must not exceed specifications.

CC127D

2. Wash the cylinder in parts-cleaning solvent.

3. Inspect the cylinder for pitting, scoring, scuffing, and

corrosion. If marks are found, repair the surface

using a #320 grit ball hone.

NOTE: To produce the proper 60° cross-hatch

pattern, use a low RPM drill (600 RPM) at the rate

of 30 strokes per minute. If honing oil is not avail-

able, use a lightweight petroleum-based oil. Thor-

oughly clean cylinder after honing using soap and

hot water. Dry with compressed air; then immedi-

ately apply oil to the cylinder bore. If the bore is

severely damaged or gouged, replace the cylinder.

CC390D

4. If any measurement exceeds the limit, the cylinder

must be replaced.

Measuring Camshaft Runout

NOTE: If the camshaft is out of tolerance, it must

be replaced.

1. Place the camshaft on a set of V blocks; then position

the dial indicator contact point against the shaft and

zero the indicator.

CC283D

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

erance must not exceed specifications.

Measuring Camshaft Lobe Height

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

ATV1013A

2. The lobe heights must be greater than minimum

specifications.

Inspecting Camshaft Bearing

Journal

1. Inspect the bearing journal for scoring, seizure

marks, or pitting.

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

found, the cylinder head assembly must be replaced.

Measuring Camshaft to

Cylinder Head Clearance

1. Loosen the jam nuts and adjuster screws.

CC005D

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

lands in the cylinder head.

3. Place the valve cover on the cylinder head and secure

with the valve cover cap screws. Tighten securely.

NOTE: Do not rotate the camshaft when measur-

ing clearance.

4. Remove the cap screws securing the valve cover to

the cylinder; then remove the valve cover and cam-

shaft.

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.

CC145D

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

camshaft.

CC287D

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

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

out of tolerance, replace the cylinder head.

Inspecting Camshaft Spring/Drive

1. Inspect the spring and unloader pin for damage.

CF061A

NOTE: With the weight extended, the unloader

pin should be flat-side out; with the weight

retracted, the unloader pin should be round-side

out.

CF060A

2. If damaged, the camshaft must be replaced.

Installing Top-Side

Components

A. Piston

B. Cylinder

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

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

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

FI626

NOTE: The piston should be installed so the IN

points towards the intake side.

2. Place the two alignment pins into position. Place a new

cylinder gasket into position; then place a piston holder

(or suitable substitute) beneath the piston skirt and

square the piston in respect to the crankcase.

MD1344

3. Lubricate the inside wall of the cylinder; then using a

ring compressor or the fingers, compress the rings

and slide the cylinder over the piston. Route the cam

chain up through the cylinder cam chain housing;

then remove the piston holder and seat the cylinder

firmly on the crankcase.

GZ142

4. Loosely install the two nuts securing the cylinder to

the right-side crankcase half.

NOTE: The two cylinder-to-crankcase nuts will be

tightened in step 9.

FI622A

CAUTION

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

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

shaft assembly may occur.

C. Cylinder Head/Camshaft

D. Cylinder Head Cover/

Rocker Arms

NOTE: Steps 1-4 in the preceding sub-section

must precede this procedure.

5. While keeping tension on the cam chain, place the

front cam chain guide into the cylinder.

FI621

6. Place a new gasket into position on the cylinder.

Place the alignment pins into position; then place the

head assembly into position on the cylinder making

sure the cam chain is routed through the chain cavity.

MD1347

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

ers. Note that the two cap screws on the right side of

the cylinder head nearest the cam sprocket are longer

than the two cap screws on the left (spark plug) side.

Tighten only until snug.

8. Install the two lower nuts securing the cylinder head

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

9. In a crisscross pattern, tighten the four cylinder head

cap screws (from step 7) to 28 ft-lb. Tighten the two

lower cylinder head nuts (from step 8) to 20 ft-lb and

the cylinder-to-crankcase nuts (from step 4) to 8 ft-

lb.

10. With the timing inspection plug removed and the cam

chain held tight, rotate the crankshaft until the piston is at

top-dead-center.

11. While holding the cam chain 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.

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 paral-

lel with the valve cover mating surface.

GZ190C

NOTE: When the camshaft assembly is seated,

make sure the alignment pin in the camshaft aligns

with the smallest hole in the sprocket.

13. With the alignment pin installed in the camshaft, loosely

place the cam sprocket (with the recessed side facing the

camshaft lobes) onto the camshaft and place it into posi-

tion with the cam chain over the sprocket.

CD463

CAUTION

Care should be taken that the bottom of the chain guide

is secured in the crankcase boss.

CAUTION

Keep tension on the cam chain to avoid damaging the

crankcase boss.

MD1359

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

inder head.

FI615

NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the

cylinder head.

NOTE: Note the position of the alignment marks

on the end of the camshaft. They must be parallel

with the 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.

15. When the camshaft assembly is seated, ensure the

following.

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward the pis-

ton).

C. Camshaft alignment marks parallel to the valve

cover mating surface.

D. Recessed side of the sprocket directed toward

the cam lobes.

E. Camshaft alignment pin and sprocket alignment

hole (smallest) are aligned.

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

covers the pin in the alignment hole.

MD1363

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

ing the sprocket and tab washer to the camshaft; then

install the cap screw and tab washer. Tighten cap

screw only until snug.

CC404D

FI612

18. Rotate the crankshaft until the second cap screw

securing the sprocket to the camshaft can be

installed; then install the cap screw (threads coated

with red Loctite #271). Tighten to 10 ft-lb; then bend

the tab to secure the cap screw.

CAUTION

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

step 13 and carefully proceed.

CAUTION

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

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

alignment pin falls out, severe engine damage will

result.

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.

20. Install the cylinder head plug with the cupped end

facing the camshaft and the opening directed down-

wards.

21. Place the cam chain tensioner assembly and gasket

into the cylinder. Tighten to 10 ft-lb.

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

screw counterclockwise to apply tension to the cam

chain; then install the cap screw plug and washer and

tighten securely.

FI608

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

adjuster screws on the rocker arms in the valve

cover.

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

ing surface of the valve cover; then place the valve

cover into position. Note that the two alignment pins

are properly positioned.

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

screws must not have pressure on them.

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

washers; then install the remaining cap screws.

Tighten only until snug.

MD1261

26. In a crisscross pattern starting from the center and

working outward, tighten the cap screws (from step

25) to 8.5 ft-lb.

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

nance).

28. Place the two tappet covers with O-rings into posi-

tion; then install and tighten the cap screws to 8.5 ft-

lb.

FI602

29. Install the spark plug and tighten securely; then

install the timing inspection plug.

Left-Side Components

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which

need to be addressed and to service only those

components. The technician should use discretion

and sound judgment.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

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.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

FI538

2. Remove the water pump housing assembly noting

the location of the longer cap screw. Account for a

gasket and two alignment pins.

FI539

FI541

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

oil pressure relief line to the engine. Account for two

crush washers and an O-ring.

FI544

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

speed sensor housing assembly. Account for two

alignment pins, a gasket, and two seal washers.

FI543

5. Remove the cap screws securing the magneto cover

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

nal cap screws and the two longer cap screws.

FI596A

6. Remove the magneto cover and account for two

alignment pins and the gasket.

D. Rotor/Flywheel

E. Starter Clutch/Gear

F. Starter Motor

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

must precede this procedure.

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

crankshaft and install the crankshaft protector.

FI549

8. Using the Magneto Rotor Remover Set, break the

rotor/flywheel loose from the crankshaft; then

remove the puller and crankshaft protector and

remove the rotor/flywheel.

FI550

9. Remove the flywheel key from the crankshaft; then

remove the starter clutch gear.

FI551A

10. Remove starter idler gears and their respective

shafts; then remove the starter motor. Account for an

O-ring on the starter drive housing.

FI555

G. Shift Shaft

H. Drive Gear

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

must precede this procedure.

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

then remove the cap screw securing the gear shift

cam plate and remove the plate from the shaft.

FI559

12. Remove the shift detent cam arm and spring.

FI560

13. Remove the snap ring securing the output drive gear

to the output shaft and remove the gear noting that

the hub flange is directed toward the crankcase.

FI564

FI566

Servicing Left-Side

Components

INSPECTING STARTER CLUTCH/

GEAR

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

and attempt to rotate the starter clutch gear clock-

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

the gear counterclockwise and it should turn freely.

If it moves or locks up both ways, the starter clutch

must be replaced.

2. Inspect the starter clutch gear for chipped or missing

teeth or discoloration/scoring of the clutch surface.

Inspect the bearing for loose, worn, or discolored

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

FI569

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

missing rollers, or discoloration. If any of the above

conditions exist, replace the starter clutch assembly.

FI572

REPLACING STARTER CLUTCH

ASSEMBLY

1. Remove the cap screws securing the starter clutch

assembly to the flywheel; then remove from the fly-

wheel.

FI570

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.

FI576A

FI578

REPLACING STARTER GEAR

BEARING

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

to support the hub around the entire circumference;

then using a suitable bearing driver, press the bearing

from the gear.

FI583

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

green Loctite #620 to the bearing outer race and

press into the gear hub until even with the lower

chamfer radius.

FI580

INSPECTING STATOR/MAGNETO

COVER ASSEMBLY

1. Inspect the stator for burned or discolored wiring, broken

or missing hold-down clips, or loose cap screws.

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

ation, roughness when rotated, and secure fit in bearing

bores.

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

chips or contamination. Do not disassemble the valve.

FI588

REPLACING STATOR COIL/

CRANKSHAFT POSITION SENSOR

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

two cap screws securing the crankshaft position sen-

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

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

remove the stator coil/crankshaft position sensor.

Account for and note the position of the harness

hold-down under the crankshaft position sensor.

FI590

3. Install the new stator 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.

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

screw. Tighten securely.

FI595A

REPLACING MAGNETO COVER

BEARINGS

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

bearing from the housing as indicated (one from out-

side and one from inside).

FI593

FI594

2. Clean the bearing bores in the housing and inspect

closely for cracks or shiny areas indicating bearing

movement. Replace the housing if any of the above

are evident.

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

bore, press a new bearing into the magneto cover

until the bearing is firmly seated in the bearing bore.

Installing Left-Side

Components

A. Starter Clutch/Gear

B. Rotor/Flywheel

1. If removed, place the crankshaft bearing retainer into

position. Apply red Loctite #271 to the three cap

screws. Install and tighten the three cap screws

securely.

MD1122

2. Install the starter motor and tighten the two cap

screws to 10 ft-lb.

3. Install the shift detent cam making sure the washer is

installed.

MD1086

4. Install the shift detent cam arm and spring.

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

ing sure to align the alignment marks.

FI559

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

FI555A

7. Install the starter clutch gear onto the crankshaft;

then install the rotor/flywheel key in the crankshaft.

FI551A

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

Tighten to 107 ft-lb.

C. Magneto Cover

D. Water Pump

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

must precede this procedure.

9. Install two alignment pins and place the magneto

cover gasket into position. Install the magneto cover.

Noting the different-lengthed 6 mm cap screws and

the location of the two internal cap screws, tighten

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

FI596A

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

nut. Tighten to 28 ft-lb.

FI547

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

neto cover; then install the water pump housing

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

FI541A

FI539

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

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

FI538

13. Connect the coolant hoses to the water pump and

secure with the hose clamps. Tighten securely.

Right-Side Components

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which

need to be addressed and to service only those

components. The technician should use discretion

and sound judgment.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Right-Side

Components

A. V-Belt Cover

B. Driven Pulley

C. Clutch Cover

1. If the engine is still in the frame, remove the cap

screw securing the brake pedal to the pedal axle.

Account for a flat washer.

KC149A

2. Remove the cap screws securing the V-belt cover to

the clutch cover; then slide the brake pedal outward

and remove the V-belt cover. Account for two align-

ment pins and a gasket.

KC142A

3. Mark the movable drive face and the fixed drive face

for installing purposes; then remove the nut holding

the movable drive face onto the crankshaft.

MD1033

4. Remove the movable drive face and spacer. Account

for the movable drive face rollers and outer drive

face cover.

MD1035

MD1034

AT THIS POINT

To service center crankcase components only, proceed

to Removing Right-Side Components.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

MD1036

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

driven face, spread the driven pulley by turning the

cap screw clockwise; then remove the V-belt.

KC132

6. Remove the fixed drive face.

MD1094

7. Remove the nut holding the driven pulley assembly;

then remove the driven pulley assembly.

MD1068

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

lips-head cap screws holding the air intake plate.

Remove the air intake plate.

MD1092

9. Remove the cap screws holding the clutch cover onto

the right-side crankcase half. Note the positions of

the different-lengthed cap screws for installing pur-

poses.

10. Using a rubber mallet, loosen the clutch cover; then

pull it away from the right-side crankcase half.

Account for two alignment pins and gasket.

MD1115

D. Centrifugal Clutch Assembly

E. Oil Pump Drive Gear

F. Oil Pump Driven Gear

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

must precede this procedure.

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

the green dot or the word OUTSIDE for installing

purposes.

MD1286

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

trifugal clutch assembly.

MD1014

MD1016

13. Remove the cam chain.

FI630

14. Remove the oil pump drive gear cap screw.

MD1018

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

MD1017

16. Remove the snap ring holding the oil pump driven

gear.

MD1019

CAUTION

Care must be taken when removing the nut; it has “left-

hand” threads.

NOTE: Always use a new snap ring when install-

ing the oil pump driven gear.

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

pin and thrust washer.

MD1020

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.

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.

MD1337

MD1208

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.

ATV1014

AT THIS POINT

To service clutch components, see Servicing Right-Side

Components sub-section.

AT THIS POINT

To service center crankcase components only, proceed

to Separating Crankcase Halves.

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.

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.

KC331A

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

terclockwise in respect to the clutch housing. If the

clutch shoe locks up or turns in both directions, the

one-way clutch must be replaced.

KC332A

INSPECTING OIL PUMP

1. Inspect the pump for damage.

2. It is inadvisable to remove the screw securing the

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

replaced.

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

nent and must be replaced as a complete assem-

bly.

DRIVEN PULLEY ASSEMBLY

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

viceable 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 crank-

case. Tighten the Phillips-head screws securely.

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.

MD1208

3. Place two alignment pins and the oil pump into posi-

tion on the crankcase and secure with the Phillips-

head screws coated with red Loctite #271. Tighten to

8 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.

NOTE: Always use a new snap ring when install-

ing the oil pump driven gear.

MD1020

MD1019

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 Loc-

tite #271) to 63 ft-lb.

MD1017

MD1018

7. Install the clutch shoe assembly on the crankshaft;

then install the flange nut (left-hand thread) (coated

with red Loctite #271). Tighten to 147 ft-lb.

NOTE: The flat side of the flange nut should be

directed towards the clutch shoe.

CAUTION

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

“left-hand” threads.

8. Install the one-way clutch making sure that the green

dot or the word OUTSIDE is directed away from the

crankcase.

MD1286

B. Clutch Cover

C. Fixed Drive Face

D. Movable Drive Face

NOTE: Steps 1-8 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.

MD1115

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

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.

MD1342

12. Place the driven pulley assembly into position and

secure with the nut (threads coated with red Loctite

#271). Tighten to 147 ft-lb.

MD1068

KC134

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.

KC137

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

direction of engine rotation.

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.

KC127

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

then making sure the splines of the clutch shaft pro-

trude through the cover plate, secure with the nut and

tighten to 147 ft-lb.

KC138

KC141

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

removed from the driven pulley face.

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.

KC142A

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

ft-lb.

Center Crankcase

Components

NOTE: This procedure cannot be done with the

engine/transmission in the frame. Complete

Removing procedures for Top-Side, Left-Side, and

Right-Side must precede this procedure.

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which

need to be addressed and to service only those

components. The technician should use discretion

and sound judgment.

Separating Crankcase

Halves

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

securing the crankcase halves noting the position of

the different-sized cap screws for joining purposes.

MD1006

MD1012

2. Using Crankcase Separator/Crankshaft Remover and

tapping lightly with a rubber mallet, separate the

crankcase halves. Account for two alignment pins.

CC869

NOTE: To keep the shaft/gear assemblies intact

for identification, tap the shafts toward the left-

side crankcase half when separating the halves.

MD1313

Disassembling

Crankcase Half

NOTE: To aid in installing, it is recommended

that the assemblies be kept together and in order.

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

FI639A

1. Remove the secondary driven shaft assembly (A)

noting the location of the front and rear bearing

locating pins and the center bearing locating ring.

FI660A

FI659A

FI661A

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

note the location of the inner bushing (1), idler shaft (2),

and outer washer (3).

FI641A

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

ing shaft (D) out of the crankcase locating boss and

allow the shift forks to disengage from the gear shift

shaft (F).

FI646

FI653A

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

outer washers.

FI650A

5. Remove the countershaft assembly (E) along with

the shift fork assembly.

FI662

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

account for a key; then remove the crankshaft bal-

ancer shaft.

MD1024

7. Using Crankcase Separator/Crankshaft Remover

with the appropriate crankshaft protector, remove the

crankshaft.

MD1330

8. Remove the secondary drive gear/secondary driven gear

retaining nut. From inside the crankcase using a rubber

mallet, drive out the output shaft assembly. Account for

the output shaft, a shim, a washer, and the nut.

Servicing Center

Crankcase Components

SECONDARY GEARS

NOTE: When checking and correcting secondary

gear backlash and tooth contact, the universal

joint must be secured to the front shaft or false

measurements will occur.

Checking Backlash

NOTE: The rear shaft and bevel gear must be

removed for this procedure. Also, always start with

the original shims on the rear shaft.

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

crankcase half to prevent runout of the secondary

transmission output shaft.

2. Install the secondary driven output shaft assembly

onto the crankcase.

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

secondary driven bevel gear (centered on the gear

tooth).

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

note the maximum backlash reading on the gauge.

5. Acceptable backlash range is 0.05-0.33 mm (0.002-

0.013 in.).

Correcting Backlash

NOTE: If backlash measurement is within the

acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing shim, measure it, and install a

new thinner shim.

2. If backlash measurement is more than specified,

remove an existing shim, measure it, and install a

thicker shim.

NOTE: Continue to remove, measure, and install

until backlash measurement is within tolerance.

Note the following chart.

Checking Tooth Contact

NOTE: After correcting backlash of the second-

ary 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 revo-

lutions in both directions.

6. Examine the tooth contact pattern in the dye and

compare the pattern to the illustrations.

CAUTION

Do not remove the remaining output shaft assembly

unless absolutely necessary. If the shaft is removed, the

shaft nut must be replaced with a new one and the shaft

must be re-shimmed.

AT THIS POINT

To service crankshaft assembly, see Servicing Center

Crankcase Components sub-section.

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

ATV-0103

ATV-0105

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 follow-

ing chart.

NOTE: To correct tooth contact, steps 1 and 2

(with NOTE) of “Correcting Backlash” must be fol-

lowed and the above “Tooth Contact/Shim Correc-

tion” chart must be consulted.

CRANKSHAFT ASSEMBLY

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.

CC290D

2. Maximum diameter must not exceed specifications.

Measuring Connecting Rod

(Small End Deflection)

1. Place the crankshaft on a set of V-blocks and mount

a dial indicator and base on the surface plate. Posi-

tion the indicator contact point against the center of

the connecting rod small end journal.

2. Zero the indicator and push the small end of the con-

necting rod away from the dial indicator.

3. Maximum deflection must not exceed specifications.

Measuring Connecting Rod

(Big End Side-to-Side)

1. Push the lower end of the connecting rod to one side

of the crankshaft journal.

2. Using a feeler gauge, measure the gap between the

connecting rod and crankshaft journal.

Tooth Contact Shim Correction

Contacts at Top Decrease Shim Thickness

Contacts at Root Increase Shim Thickness

CAUTION

After correcting tooth contact, backlash must again be

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

recting backlash/correcting tooth contact procedures

until they are both within tolerance values.

CC289D

3. Acceptable gap range must be within specifications.

Measuring Crankshaft (Runout)

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

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

Position the indicator contact at point 1 of the crank-

shaft.

H1-003A

3. Zero the indicator and rotate the crankshaft slowly.

4. Maximum runout must not exceed specifications.

NOTE: Proceed to check runout on the other end

of the crankshaft by positioning the indicator con-

tact at point 2 and following steps 3-4.

Measuring Crankshaft (Web-to-

Web)

1. Using a calipers, measure the distance from the out-

side edge of one web to the outside edge of the other

web.

H1-006

2. Acceptable width range must be within specifica-

tions.

COUNTERSHAFT

Disassembling

1. Remove the reverse driven gear dog; then remove

the circlip securing the reverse driven gear.

FI663

FI664

2. Remove the splined washer; then remove the reverse

driven gear along with the bearing and bushing.

CAUTION

Care should be taken to support the connecting rod

when rotating 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.

FI665

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

low driven gear along with the bearing and bushing.

FI666

FI667

4. Remove the splined washer; then remove the circlip

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

ing dog.

FI668

FI669

5. Remove the circlip securing the high driven gear;

then remove a washer, the high driven gear along

with the bearing and bushing, and remove the high

driven washer.

FI670

FI671

ASSEMBLING

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

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

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

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

FI671A

FI670

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

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

washer (8).

FI668A

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

gear (11) on the countershaft; then install splined

washer (12).

FI667A

FI666

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

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

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

FI665A

FI664

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

shift forks and shift shaft into position.

FI663

FI662

NOTE: The countershaft assembly is now ready

to be installed.

Assembling Crankcase

Half

NOTE: For ease of assembly, install components

on the right-side crankcase half.

NOTE: If the output shaft was removed, make

sure that the proper shim is installed.

1. Install the output shaft into the crankcase making

sure the two gears, shim, washer, and nut are in the

correct order.

MD1199

MD1079

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

lb. Using a punch, peen the nut.

MD1333

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

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

oil begins to smoke; then slide the crankshaft assem-

bly into place.

MD1334

NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft

installer.

4. Rotate the crankshaft so the counterweight is toward

the rear of the engine. Install the crank balancer

shaft.

MD1024

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

the gear and aligning the timing marks, slide the gear

into place.

FI658

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

locating boss and with a washer on each end, install

in the crankcase.

FI652A

7. Place the shift forks into position on the assembled

countershaft and install into the crankshaft as an

assembly.

FI662

FI653

8. Align the shift forks to allow engagement with the shift

cam; then engage the shift forks and slide the shift fork

shaft into the locating boss in the crankcase.

FI653A

FI655A

9. Install the input driveshaft.

FI646

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

washer (3).

FI641A

FI645

11. Install the secondary output driveshaft assembly into

the crankcase half making sure the front and rear

bearing alignment pins are seated in the recesses;

then install the center carrier bearing alignment C-

ring.

FI660A

FI659A

FI661A

Joining Crankcase

Halves

1. Verify that the two alignment pins (A) are in place

and that both case halves are clean and grease free.

Apply Loctite #5900 or suitable substitute sealant to

the mating surfaces. Place the right-side half onto the

left-side half.

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.

FI639D

2. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.

3. From the right side, install the crankcase cap screws

noting the location of the different-sized cap screws;

then tighten only until snug.

NOTE: Rotate the shafts back and forth to ensure

no binding or sticking occurs while tightening the

cap screws.

MD1008

4. From the left side, install the remaining crankcase

cap screws; then tighten only until snug.

NOTE: Rotate the shafts back and forth to ensure

no binding or sticking occurs while tightening the

cap screws.

CC871

5. In a crisscross 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.

Servicing Engine (700)

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.

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 inspec-

tion plug; then using a socket and ratchet, rotate the

crankshaft to top-dead-center of the compression

stroke.

1. Remove the two tappet covers.

AT THIS POINT

After completing center crankcase components, pro-

ceed to Installing Right-Side Components, to Installing

Left-Side Components, and to Installing Top-Side Com-

ponents.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

CC001D

NOTE: Keep the mounting hardware with the covers

for assembly purposes or thread them back into the

head to keep them separated.

2. Remove the 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.

H1-013A

4. Remove the valve cover. Account for and note the

orientation of the cylinder head plug. Note the loca-

tion of the two alignment pins.

CD206

CD211A

5. Loosen the cap screw on the end of the tensioner;

then remove the two cap screws securing the ten-

sioner adjuster assembly and remove the assembly.

Account for a gasket.

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.

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.

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.

FI620

9. Remove the cap screw securing the chain tensioner

(account for a washer); then remove the tensioner.

FI617

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

cylinder.

CC017D

CC018D

11. Remove the four cylinder head bolts.

NOTE: Account for rubber O-rings.

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.

CC020D

CC022D

C. Cylinder

D. Piston

NOTE: Steps 1-12 in the preceding sub-section

must precede this procedure.

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 crank-

case.

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.

CC024D

CC025D

CC026D

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

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.

AT THIS POINT

To service valves and cylinder head, see Servicing Top-

Side Components sub-section.

AT THIS POINT

To inspect cam chain guide, see Servicing Top-Side

Components sub-section.

AT THIS POINT

To service cylinder, see Servicing Top-Side Compo-

nents sub-section.

CAUTION

When removing the cylinder, be sure to support the pis-

ton to prevent damage to the crankcase and piston.

CC033D

NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install the Con-

necting Rod Holder.

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.

Servicing Top-Side

Components

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 cylin-

der head assembly must be replaced.

1. Wash the valve cover in parts-cleaning solvent.

2. Place the valve cover on the Surface Plate covered

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

pressure, move the valve cover in a figure eight

motion. Inspect the sealing surface for any indication

of high spots. A high spot can be noted by a bright

metallic finish. Correct any high spots before assem-

bly by continuing to move the valve cover in a figure

eight motion until a uniform bright metallic finish is

attained.

CC130D

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 origi-

nal position.

1. Using a valve spring compressor, compress the valve

springs and remove the valve cotters. Account for an

upper spring retainer.

CC132D

2. Remove the valve seal and the lower remaining

spring seat. Discard the valve seal.

CAUTION

Do not allow the connecting rod to go down inside the

crankcase. If the rod is down inside the crankcase and

the crankshaft is rotated, severe damage will result.

AT THIS POINT

To service piston, see Servicing Top-Side Components

sub-section.

AT THIS POINT

To service center crankcase components only, proceed

to Removing Left-Side Components.

CAUTION

Do not remove an excessive amount of the sealing sur-

face or damage to the camshaft will result. Always

check camshaft clearance when resurfacing the valve

cover.

CAUTION

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

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

the sealing surface may result.

CC136D



NOTE: The valve seals must be replaced.

3. Remove the valve springs; then invert the cylinder head

and remove the valves.

Measuring Valve Stem Runout

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

check the valve stem runout using a dial indicator.

ATV-1082

2. Maximum runout must not exceed specifications.

Measuring Valve Stem Outside

Diameter

1. Using a micrometer, measure the valve stem outside

diameter.

2. Acceptable diameter range must be within specifica-

tions.

Measuring Valve Face/Seat Width

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

ATV-1004

2. Acceptable width ranges must not exceed specifica-

tions.

Measuring Valve Face Radial Runout

1. Mount a dial indicator on the surface plate; then

place the valve stem on a set of V blocks.

2. Position the dial indicator contact point on the out-

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

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.

Measuring Valve Guide/Valve Stem

Deflection (Wobble Method)

1. Mount a dial indicator and base on the surface plate;

then place the cylinder head on the surface plate.

2. Install the valve into the cylinder head; then position

the dial indicator contact point against the outside

edge of the valve face. Zero the indicator.

CC131D

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

bottom.

4. Maximum “wobble” deflection must not exceed

specifications.

Measuring Valve Guide

(Inside Diameter)

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

guide bore; then remove the gauge and measure it

with a micrometer.

2. Acceptable inside diameter range must be within

specifications.

3. If a valve guide is out of tolerance, it must be

replaced.

Servicing Valves/Valve Guides/Valve

Seats

If valves, valve guides, or valve seats require servicing or

replacement, Arctic Cat recommends that the compo-

nents be taken to a qualified machine shop for servicing.

Measuring Rocker Arm

(Inside Diameter)

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

the rocker arm.

2. Acceptable inside diameter range must be within

specifications.

Measuring Rocker Arm Shaft

(Outside Diameter)

1. Using a micrometer, measure the outside diameter of

the rocker arm shaft.

2. Acceptable outside diameter range must be within

specifications.

Installing Valves

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

then place a lower spring seat and valve guide seal

over each valve guide.

CC144D

2. Insert each valve into its original location.

3. Install the valve springs with the painted end of the

spring facing away from the cylinder head.

NOTE: If the paint is not visible, install the ends of

the springs with the closest wound coils toward the

head.

ATV-1011A

4. Place a spring retainer over the valve springs; then

using the valve spring compressor, compress the

valve springs and install the valve cotters.

CC132D

PISTON ASSEMBLY

NOTE: Whenever a piston, rings, or pin are out of

tolerance, they must be replaced.

Cleaning/Inspecting Piston

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the dome of the piston.

2. Inspect the piston for cracks in the piston pin, dome,

and skirt areas.

3. Inspect the piston for seizure marks or scuffing.

Repair with #400 grit wet-or-dry sandpaper and

water or honing oil.

NOTE: If scuffing or seizure marks are too deep to

correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indicates

worn piston rings or an out-of-round cylinder.

Removing Piston Rings

1. Starting with the top ring, slide one end of the ring

out of the ring-groove.

CAUTION

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

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

to grind the valves or severe engine damage may occur.

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.

2. Using the sharpened ring as a tool, clean carbon from

the ring-grooves. Be sure to position the ring with its

tapered side up.

Measuring Piston-Ring End Gap

(Installed)

1. Place each 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 speci-

fications.

CC280D

Measuring Piston Pin (Outside

Diameter) and Piston-Pin Bore

1. Measure the piston pin outside diameter at each end

and in the center. If measurement is not within speci-

fications, the piston pin must be replaced.

ATV-1070

2. Insert an inside dial indicator into the piston-pin

bore. The diameter must not exceed specifications.

Take two measurements to ensure accuracy.

ATV-1069

Measuring Piston Skirt/Cylinder

Clearance

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

CC127D

2. Measure the corresponding piston diameter at the

recommended point above the piston skirt at a right

angle to the piston-pin bore. Subtract this measure-

ment from the measurement in step 1. The difference

(clearance) must not exceed specifications.

CAUTION

Improper cleaning of the ring-grooves by the use of the

wrong type of ring-groove cleaner will result in severe

damage to the piston.

Installing Piston Rings

1. Install ring expander (4) in the bottom groove of the

piston; then install the thin oil rings (3) over the

expander making sure the expander ends do not

overlap. Stagger the end gaps of the upper and lower

thin oil rings according to the illustration.

ATV-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.

ATV-1024A

ATV-1024B

CYLINDER/CYLINDER HEAD

ASSEMBLY

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

they must be replaced as an assembly.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the combustion chamber

being careful not to nick, scrape, or damage the com-

bustion chamber or the sealing surface.

2. Inspect the spark plug hole for any damaged threads.

Repair damaged threads using a “heli-coil” insert.

3. Place the cylinder head on the Surface Plate covered

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

pressure, move the cylinder head in a figure eight

motion. Inspect the sealing surface for any indication

of high spots. A high spot can be noted by a bright

metallic finish. Correct any high spots before assem-

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

ure eight motion until a uniform bright metallic

finish is attained.

CC128D

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion

chamber.

2. Lay a straightedge across the cylinder head; then

using a feeler gauge, check the distortion factor

between the head and the straightedge.

3. Maximum distortion must not exceed specifications.

CAUTION

Incorrect installation of the piston rings will result in

engine damage.

CAUTION

The cylinder head studs must be removed for this pro-

cedure.

CAUTION

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

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

the sealing surface may result.

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 continu-

ing to move the cylinder in a figure eight motion

until a uniform bright metallic finish is attained.

CC129D

Inspecting Cam Chain Guide

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

chips.

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

Inspecting Cylinder

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

gauge, measure the cylinder bore diameter in three

locations from top to bottom and again from top to

bottom at 90° from the first measurements for a total

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

ness) is the difference between the highest and low-

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

must not exceed specifications.

CC127D

2. Wash the cylinder in parts-cleaning solvent.

3. Inspect the cylinder for pitting, scoring, scuffing, and

corrosion. If marks are found, repair the surface

using a #320 grit ball hone.

NOTE: To produce the proper 60° cross-hatch pat-

tern, use a low RPM drill (600 RPM) at the rate of 30

strokes per minute. If honing oil is not available, use

a lightweight petroleum-based oil. Thoroughly clean

cylinder after honing using soap and hot water. Dry

with compressed air; then immediately apply oil to

the cylinder bore. If the bore is severely damaged or

gouged, replace the cylinder.

CC390D

4. If any measurement exceeds the limit, 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.

CAUTION

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

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

the sealing surface may result.

CC283D

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

out must not exceed specifications.

Measuring Camshaft Lobe Height

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

ATV1013A

2. The lobe heights must be greater than minimum

specifications.

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. Remove the adjuster screws and jam nuts.

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 cam-

shaft.

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.

CC145D

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

camshaft.

CC287D

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

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

out of tolerance, replace the cylinder head.

Inspecting Camshaft Spring/Drive

1. Inspect the spring and drive pin for damage.

CF061A

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.

CC032D

2. Place the two alignment pins into position. Place the

cylinder gasket into position; then place a piston

holder (or suitable substitute) beneath the piston skirt

and square the piston in respect to the crankcase.

CF083

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.

CC024D

4. Loosely install the two nuts which secure the cylin-

der to the crankcase.

NOTE: The two cylinder-to-crankcase nuts will be

tightened in step 11.

CC023D

CAUTION

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

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

shaft assembly may occur.

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.

CF058A

7. Place a new head gasket into position on the cylin-

der. Place the alignment pins and four O-rings into

position; then place the head assembly into position

on the cylinder.

CC020D

CF057A

CF289A

8. Install the four cylinder head cap screws and wash-

ers. Tighten only until snug.

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 incre-

ments, 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-to-

crankcase 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 top-

dead-center.

13. Install the rear cam chain tensioner guide into the cylin-

der head. Install the pivot cap screw and washer.

CD461

NOTE: At this point, oil the camshaft journals, cam

lobes, and the three seating surfaces on the cylinder.

CAUTION

Care should be taken that the bottom of the chain guide

is secured in the crankcase boss.

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.

732-307B

15. With the cam lobes directed down (toward the pis-

ton), 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 cam-

shaft 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.

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 cam-

shaft/sprocket assembly onto the cylinder ensuring

the following.

CF013A

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward the pis-

ton).

C. Camshaft alignment marks parallel to the valve

cover mating surface.

D. Recessed side of the sprocket directed toward the

cam lobes.

E. Camshaft alignment pin and sprocket alignment

hole (smallest) are aligned.

17. Place the tab-washer onto the sprocket making sure it

covers the pin in the alignment hole.

ATV1027

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.

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.

CAUTION

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

step 12 and carefully proceed.

CAUTION

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

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

alignment pin falls out, severe engine damage will

result.

CD465

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.

CD466

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

inder head.

CC012D

22. Install the cylinder head plug in the cylinder head

with the open end facing downward and toward the

inside.

CD468

23. Remove the cap screw from the end of the chain ten-

sioner; then using a flat-blade screwdriver, rotate the

adjuster screw inside the tensioner clockwise until

the screw bottoms.

CD501

NOTE: The adjuster shaft will be drawn into the ten-

sioner 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 gas-

ket into position on the cylinder and secure with the

two cap screws.

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.

CAUTION

The open end of the plug must be positioned downward.

CD470

CD471

26. Loosen the four adjuster screw jam nuts; then loosen

the four adjuster screws on the rocker arms in the

valve cover.

CC005D

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

ing surfaces of the cylinder head and valve cover.

CC275D

28. Place the valve cover into position.

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 wash-

ers; then install the remaining cap screws. Tighten

only until snug.

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 Mainte-

nance).

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

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 dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Left-Side

Components

A. Outer Magneto Cover

B. Water Pump

C. Cover

D. Rotor/Flywheel

1. Remove the four cap screws securing the outer mag-

neto cover to the left-side cover; then remove the

outer magneto cover.

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 trig-

ger. Account for the gasket.

NOTE: It may be necessary to use a small two-jaw

puller to remove the trigger.

CD920

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.

6. Remove the cap screws securing the left-side cover

to the crankcase noting the location of the different-

sized cap screws for installing purposes.

7. Using an appropriate side case puller, remove the

side cover. Account for a gasket and two alignment

pins.

8. Remove the nut securing the magneto rotor to the

crankshaft; then install the magneto rotor puller

adapter.

NOTE: The puller has left-hand threads.

9. Using Magneto Rotor Remover Set and the appropri-

ate crankshaft protector, remove the rotor/flywheel

assembly from the crankshaft. Account for the key;

then remove the starter clutch gear assembly and

washer.

PR441

CD939A

CD940A

10. Remove the two starter gears from the crankcase not-

ing the direction of the beveled side of the gears for

installing purposes; then remove the two starter gear

shafts.

CD136

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.

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.

CD952A

NOTE: There is an oil passage beneath the driven

gear/drive gear assembly. This passage should be

plugged prior to removing the driven gear and drive

gear. Failure to do so could result in the loss of an

alignment pin into the crankcase.

13. Remove the shift shaft noting the timing marks for

assembling purposes. Account for two washers.

PR430A

14. Remove the gear shift cam plate and account for a

washer; then remove the cam stopper and cam stop-

per spring. Account for two washers.

PR434A

Servicing Left-Side

Components

INSPECTING STARTER CLUTCH/

GEAR

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

and attempt to rotate the starter clutch gear clock-

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

the gear counterclockwise and it should turn freely.

If it moves or locks up both ways, the starter clutch

must be replaced.

2. Inspect the starter clutch gear for chipped or missing

teeth or discoloration/scoring of the clutch surface.

Inspect the bearing for loose, worn, or discolored

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

FI569

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

missing rollers, or discoloration. If any of the above

conditions exist, replace the starter clutch assembly.

FI572

REPLACING STARTER CLUTCH

ASSEMBLY

1. Remove the cap screws securing the starter clutch

assembly to the flywheel; then remove from the fly-

wheel.

FI570

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.

FI576A

FI578

REPLACING STARTER GEAR

BEARING

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

to support the hub around the entire circumference;

then using a suitable bearing driver, press the bearing

from the gear.

FI583

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

green Loctite #620 to the bearing outer race and

press into the gear hub until even with the lower

chamfer radius.

FI580

INSPECTING STATOR COIL/

MAGNETO COVER ASSEMBLY

1. Inspect the stator coil for burned or discolored wir-

ing, broken or missing hold-down clips, or loose cap

screws.

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

coloration, roughness when rotated, and secure fit in

bearing bores.

REPLACING STATOR COIL/

CRANKSHAFT POSITION SENSOR

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

two cap screws securing the crankshaft position sen-

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

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

remove the stator coil/crankshaft position sensor.

Account for and note the position of the harness

hold-down under the crankshaft position sensor.

FI590

3. Install the new stator coil assembly and secure with

three new “patch-lock” cap screws. Tighten to 15 ft-

lb.

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

tion; then install the crankshaft position sensor and

secure with two cap screws. Tighten securely.

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

cap screw. Tighten securely.

FI595A

Installing Left-Side

Components

NOTE: Plug the oil passage in the crankcase hous-

ing 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 fac-

ing outward as noted in removing); then secure with

the snap ring.

CD950A

CD952A

CD949

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

facing outward.

2. Install the water pump drive gear drive pin and the

drive gear (with the flat side of the gear facing out-

ward as noted in removing); then secure with the

snap ring.

CD946A

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 intermedi-

ate gear facing inward as noted in removing).

CD139

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.

CD948A

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.

100

PR433A

CD934

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.

PR434A

NOTE: Rotate the shift cam plate to ensure it ratch-

ets 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.

CD954A

CD927A

8. Lubricate the magneto cover gasket with fresh

engine oil; then place it into position on the two

alignment pins. Make sure the outer shift shaft

washer is in place.

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 counter-

shaft splines and install the trigger. Secure with a flat

washer and outer snap ring.

101

GZ253

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.

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 cyl-

inder head making sure the O-ring is properly posi-

tioned.

16. Place the outer magneto cover into position on the

left-side cover; then tighten four cap screws to 6 ft-

lb.

Right-Side Components

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

disassemble only those components which need to

be addressed and to service only those components.

The technician should use discretion and sound

judgment.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Right-Side

Components

A. V-Belt Cover

B. Driven Pulley

C. Clutch Cover

D. 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.

CD079

2. Remove the nut and washer securing the movable drive

face; then remove the face. Account for a spacer.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

102

CD963

CD966A

3. Remove the V-belt.

4. Remove the nut securing the fixed driven assembly; then

remove the assembly.

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.

CD973A

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.

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.

CAUTION

Care must be taken when removing the cover so the

cover gasket is not damaged.

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

103

CF085

CC596

NOTE: Account for and inspect the clutch housing

seal.

CF088A

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

shoe assembly (C).

PR410A

10. Remove the cap screw securing the oil pump drive

gear (B). Account for a cap screw, washer, pin, and

spacer.

CC606

CD987

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 align-

ment pins.

104

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.

CD984

CD895A

13. Using an impact driver, remove the three torx-head

screws securing the oil pump; then remove the

pump.

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.

ATV1014

INSPECTING CLUTCH HOUSING

1. Inspect the clutch housing for burns, grooving,

cracks, or uneven wear.

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

must be replaced.

INSPECTING PRIMARY

ONE-WAY DRIVE

1. Insert the drive into the clutch housing.

2. Rotate the inner race by hand and verify the inner

race rotates only one direction.

3. If the inner race is locked in place or rotates both

directions, the drive assembly must be replaced.

105

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.

CC446D

DRIVEN PULLEY ASSEMBLY

NOTE: The driven pulley is a non-serviceable com-

ponent. 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

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.

CD999

2. Install the oil pump onto the engine; then tighten the

screws (coated with red Loctite #271) to 8 ft-lb.

CD988

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.

CD992

CD991

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.

106

CD985A

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.

PR410A

6. Install the clutch cover alignment pins into the crank-

case, apply oil to the cover gasket, and install the

gasket onto the crankcase.

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

assembly.

PR399A

8. Lightly grease the clutch housing seal; then insert the

left fixed-drive spacer.

CF088A

CF085A

9. Apply grease to the outer edges of the clutch hous-

ing; then from inside the clutch cover, install the

clutch housing into the cover using a rubber mallet.

10. Place the clutch cover/housing assembly into posi-

tion 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.

CAUTION

When installed correctly, the green alignment dot (or the

word OUTSIDE) on the one-way clutch is visible.

107

H1-023

11. Place the driven pulley assembly into position and

secure with the nut. Tighten to 162 ft-lb.

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.

CF270A

H1-020A

14. Place the V-belt into position on the driven pulley

and over the front shaft.

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.

FI428A

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

from between the driven pulley faces.

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 mak-

ing sure the different-lengthed cap screws are in their

proper location. Tighten the cap screws to 8 ft-lb.

CAUTION

Make sure the splines extend beyond the drive face or a

false torque reading and spline damage may occur.

108

CD083

Center Crankcase

Components



NOTE: This procedure cannot be done with the engine/

transmission in the frame. Complete Removing proce-

dures for Top-Side, Left-Side, and Right-Side must pre-

cede this procedure.



NOTE: For efficiency, it is preferable to remove and dis-

assemble only those components which need to be

addressed and to service only those components. The

technician should use discretion and sound judgment.

Separating Crankcase

Halves

1. Remove the right-side cap screws securing the crankcase

halves. Note the location of the different-lengthed cap

screws.

2. Remove the left-side cap screws securing the crankcase

halves. Note the location of the different-lengthed cap

screws.

3. Using the Crankcase Separator/Crankshaft Remover and

tapping lightly with a rubber mallet, separate the crank-

case halves. Account for two alignment pins.



NOTE: To keep the shaft/gear assemblies intact for

identification, tap the shafts toward the left-side crank-

case half when separating the halves.

PR786

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.

PR787A

1. Remove the secondary driven shaft assembly (A)

noting the location of the bearing locating pins.

Account for the bearing C-ring.

PR787B

2. Remove the reverse idler gear assembly (F). Account

for all washers, shaft, bushing, and the gear.

CC668

KEY

A. Secondary Driven Shaft

Assembly

B. Crank Balancer Assembly

C. Crankshaft

D. Countershaft Assembly

E. Driveshaft

F. Reverse Idler Gear Assembly

G. Gear Shift Shaft

H. Shift Shaft with 2 Forks

109

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.

DE677A

5. Remove the countershaft assembly (D). Account for

a washer on each end of the countershaft.

CC674

NOTE: Do not disassemble the countershaft assem-

bly unless necessary. If necessary, see Servicing

Center Crankcase Components sub-section.

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

remove the driveshaft.

CC675

7. Note the timing marks on the crank balancer assem-

bly (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.

CD826

8. Remove the crank balancer.

NOTE: There is a flat spot on the crank balancer

bearing flange to allow clearance past the crankshaft.

CD832B

9. Remove the snap ring securing the water pump

driven gear shaft.

10. Using a hydraulic press, remove the crankshaft

assembly.

NOTE: Use a protective end cap to prevent damage

to the crankshaft threads.

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.

PR406

110

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

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.

MT011A

2. Using a suitable press, install the driven gear (C) on

the shaft until the gear firmly seats on the shoulder of

the shaft.

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.

MT012

MT008A

4. Install a new seal (F), output yoke (G), and nut (H)

and tighten to 74 ft-lb.

CAUTION

Unless the secondary drive gear, bevel gear, or bear-

ings require service, do not remove the secondary drive

assembly from the case. If removed, bevel gear back-

lash will have to be adjusted requiring re-shimming of

the drive bevel gear shaft.

111

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 rota-

tions in both directions. Gear contact should extend

from the root to the top of the gear teeth.

MT016A

6. To adjust tooth contact, use the following chart to

correctly shim the driven shaft.

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 ft-

lb.

2. Install the secondary drive bearing support; then

install the secondary driven output shaft into the

crankcase.

3. Mount the dial indicator so the tip is contacting a

tooth on the secondary drive bevel gear.

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

note the maximum backlash reading on the gauge.

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.

After backlash and tooth contact are within specifica-

tions, 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 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.

Tooth Contact Shim Correction

Contact at Top Increase Shim Thickness

Contact at Root Decrease Shim Thickness

Backlash Measurement 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

112

CC290D

2. Maximum diameter must not exceed specifications.

Measuring Connecting Rod

(Small End Deflection)

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

dial indicator and base on the surface plate. Position

the indicator contact point against the center of the

connecting rod small end journal.

2. Zero the indicator and push the small end of the con-

necting rod away from the dial indicator.

3. Maximum deflection must not exceed specifications.

Measuring Connecting Rod

(Big End Side-to-Side)

1. Push the lower end of the connecting rod to one side

of the crankshaft journal.

2. Using a feeler gauge, measure the gap between the

connecting rod and crankshaft journal.

CC289D

3. Acceptable gap range must not exceed specifica-

tions.

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 crank-

shaft.

H1-003

3. Zero the indicator and rotate the crankshaft slowly.

4. Maximum runout must not exceed specifications.

NOTE: Proceed to check runout on the other end of

the crankshaft by positioning the indicator contact at

point 2 and following steps 3-4.

Measuring Crankshaft (Web-to-

Web)

1. Using a calipers, measure the distance from the out-

side edge of one web to the outside edge of the other

web.

H1-005

2. Acceptable width range must not exceed specifica-

tions.

CAUTION

Care should be taken to support the connecting rod

when rotating the crankshaft.

113

COUNTERSHAFT

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.

GZ283A

2. Remove the drive gear; then remove the snap ring

securing the reverse driven gear dog and bushing to

the countershaft.

GZ296

GZ312

3. Remove the reverse driven gear dog.

GZ313A

4. Remove the snap ring securing the reverse driven

gear and washer; then remove the washer and gear.

GZ314

5. Remove the reverse driven washer; then remove the

low driven gear locking washer.

GZ320

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.

114

GZ319

GZ318A

6. Remove the low driven gear. Account for a bearing,

bushing, and thrust washer.

GZ316

Assembling

1. From the drive gear end, install a thrust washer,

bushing, and bearing; then install the low driven gear

and washer.

GZ317A

GZ318

2. Install the low driven gear locking washer; then

install the inner reverse driven gear washer.

GZ319B

GZ320B

3. Install the reverse driven bushing and bearing; then

install the reverse driven gear.

115

GZ286A

GZ287

4. Install the outer reverse driven washer; then secure

the reverse driven gear assembly with a snap ring.

GZ288A

GZ314

5. Install the reverse driven gear dog onto the counter-

shaft and secure with a snap ring.

GZ313A

GZ312

6. From the opposite end of the countershaft, install the

high/low driven gear dog (A), thrust washer (B),

bushing (C), bearing (D), high/low driven gear (E),

and spacer washer (F).

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

1. Install the secondary drive gear assembly into the

crankcase.

116

MT014

2. Apply a liberal amount of engine oil to the crank-

shaft bearing. Using a propane torch, heat the bear-

ing until the oil begins to smoke; then slide the

crankshaft assembly into place.

CC688

CC689

NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft install-

ing tool.

3. Install the crank balancer.

CD832B

NOTE: It will be necessary to rotate the crank bal-

ancer 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 align-

ment dots on the crank balancer gear and the crank-

shaft gear align.

CD826A

5. Install the driveshaft.

CC675

6. Place a washer on each end of the countershaft

assembly; then install the assembly.

117

CC674

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.

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.

CC669

9. Install the reverse idler gear assembly noting the

positioning of the two washers, gear, bushing, and

shaft.

CC668

10. Install the front and rear secondary driven shaft

assemblies into the left side of the crankcase making

sure the bearing locating pins are toward the top of

the crankcase and the bearing C-ring is fully seated

in the crankcase.

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.

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.

118

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 cor-

rectly 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.

Installing Engine/

Transmission



NOTE: Arctic Cat recommends new gaskets and O-

rings 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.

2. Tighten the flange nuts on the rear cradle to 25 ft-

lb; then tighten the nut on the front through-bolt to

40 ft-lb.

HDX157A

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 seal in the cylinder head and a

new grafoil seal on the muffler end of the exhaust

pipe and install the exhaust pipe. Secure with two

exhaust springs and two cap screws tightened to 20

ft-lb.

HDX153A

HDX154

6. Install the O2 sensor and tighten the sensor to 19

ft-lb. Connect the harness to the sensor.

7. Install the forward exhaust pipe heat shield and

secure with the machine screws. Tighten securely.

AT THIS POINT

After completing center crankcase components, pro-

ceed to Installing Right-Side Components, to Installing

Left-Side Components, and to Installing Top-Side Com-

ponents.

119

HDX152A

8. Install the CVT cooling ducts on the V-bolt hous-

ing and secure with clamps. Tighten securely.

Install an appropriate nylon tie to secure the

exhaust duct.

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.

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 posi-

tion switch connector.

HDX252A

HDX253A

11. On the left side, connect the ECT sensor connec-

tor, speed sensor connector, and spark plug cap.

HDX135A

HDX137A

12. Install the throttle body into the intake manifold boot

and secure with the clamp. Tighten to 30 in.-lb.

700

500

120

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.

HDX148A

14. Connect the IAT sensor connector to the IAT sen-

sor and the crankcase breather tube to the crank-

case; then install the air filter intake tube and

secure with a clamp and sheet metal 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.

HDX138B

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.

HDX136A

17. Pour the recommended amount of oil and coolant

into the engine and radiator; then loosen the cool-

ant bleed screw to allow trapped air to escape.

When clear coolant flows, tighten the bleed screw.

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.

121

Fuel/Lubrication/Cooling

SPECIAL TOOLS

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

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Department.

Electronic Fuel Injection

TROUBLESHOOTING

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

tening 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.

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 contami-

nation. 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.

2. Remove the seat, seat back, and seat base; then dis-

connect the battery.

3. Remove the air inlet boot between the air filter and

throttle body; then disconnect the MAP sensor con-

nector (A), fuel injector connector (B), and ISC con-

nector (C).

HDX048A

HDX043A

4. Remove the screw from the throttle arm cover and

remove the cover; then loosen the jam nut and dis-

connect the throttle cable.

HDX044A

5. Slowly disconnect the gasline hose connector from

the fuel rail.

Description p/n

Oil Pressure Test Kit 0644-495

Tachometer 0644-275

! 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 leak-

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

etc., in the area.

! 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.

! WARNING

Gasoline may be under pressure. Place an absorbant

towel under the connector to absorb any gasoline spray

when disconnecting.

122

FI092A

6. Loosen the clamp securing the throttle body to the

intake manifold boot and remove the throttle body

assembly.

7. Use tape to cover and seal the intake opening.

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.

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

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.

PR698A

3. Remove the outer cap screw securing the front tank

hold-down; then swing the hold-down to the left.

PR167A

PR170

4. Remove four press-nuts securing the gas cap filler

panel; then remove the gas cap and panel. Install the

gas cap.

PR168

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.

! 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.

123

5. Remove the joining cap screw and nut from the rear

gas tank hold-down strap; then remove the inside

hold-down strap.

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 sec-

tion).

INSTALLING

1. Place the gas tank into position in the vehicle; then

install the inside rear hold-down strap.

PR173

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.

PR171

3. Install the rear hold-down strap joining cap screw and

nut. Do not tighten at this time.

PR699A

4. Place the gas cap filler panel into position; then if neces-

sary, position the gas tank so the filler panel and filler

neck are not binding or rubbing.

PR176

! 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.

124

5. Secure the filler panel with four press-nuts; then

tighten the hardware securing the hold-down straps

(from steps 2-3) securely.

PR166A

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.

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

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.

Oil Filter/Oil Pump

NOTE: Whenever internal engine components

wear excessively or break and whenever oil is con-

taminated, the oil pump should be replaced.

TESTING OIL PUMP PRESSURE

NOTE: The engine must be warmed up to operat-

ing temperature (cooling fan cycling) for this test.

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

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 install-

ing 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 run-

ning at 3000 RPM, the pressure gauge must show

0.7-1.4 kg/cm2 (10-20 psi).

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

1. Remove the oil pump from the engine (see Right-

Side Components in the Engine/Transmission sec-

tion).

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

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.

125

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

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 pres-

ent, 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.

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.

HDX162A

2. Remove four torx-head screws (A) securing the under-

hood storage box to the frame; then remove two cap

screws with nuts (B) at the front of the storage box.

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.

PR186

4. Drain the coolant into a suitable container; then discon-

nect the cooling fan wire connector from the main har-

ness.

PR183A

5. Remove the two shoulder bolts and nuts securing the

radiator to the frame; then disconnect the upper and

lower coolant hoses.

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.

126

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 contami-

nants.

2. Inspect the radiator for leaks and damage.

3. Inspect all hoses for cracks and deterioration.

4. Inspect all fasteners and grommets for damage or wear.

INSTALLING

1. Place the radiator into position making sure the grom-

mets are correctly installed; then secure to the mounts

with the two shoulder bolts and nuts. Tighten securely.

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.

PR183A

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.

PR187

6. Install the two sheet metal screws in the dash.

Tighten securely.

7. Start the engine and warm up to operating tempera-

ture; 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 thermo-

stat with seal.

INSPECTING

1. Inspect the thermostat for corrosion, wear, or spring

damage.

2. Using the following procedure, inspect the thermo-

stat for proper operation.

A. Suspend the thermostat in a container filled with

water.

B. Heat the water and monitor the temperature with a

thermometer.

C. The thermostat should start to open at 71.0-86.0°

C (160-187° F).

D. If the thermostat does not open, it must be

replaced.

3. Inspect all coolant hoses, connections, and clamps

for deterioration, cracks, and wear.

127

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.

PR281A

2. Fill the cooling system with the recommended

amount of antifreeze. Check for leakage.

Fan

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.

Water Pump

NOTE: The water pump is not a serviceable com-

ponent. If the pump is defective or if the mechani-

cal 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.

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.

PR132

5. Remove the two cap screws securing the water pump

to the engine; then remove the water pump.

CC786A

INSTALLING

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

cap screws tightened to 8 ft-lb.

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.

128

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.

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.

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 Electri-

cal System section).

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

viceable components. If either component fails, it must

be replaced.

TESTING

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

tary “whirring” sound of the pump building pressure.

If the sound is heard (10 seconds), no electrical

checks are necessary. Turn the ignition switch OFF.

2. Disconnect the gasline hose from the fuel rail; then

install a suitable pressure gauge.

FI092A

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

pressure should build until the pump shuts off. Pres-

sure should read 3.0 kg/cm2 (43 psi).

4. If the pump is not running, disconnect the fuel pump/

sensor connector by reaching under the rear rack

from behind.

5. Connect a multimeter to the power supply leads with

the red tester lead to the red wire and the black tester

lead to the black wire; then turn the ignition switch to

the ON position. The meter should read battery volt-

age. If battery voltage is indicated and the fuel pump

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

tery voltage is indicated, check the ECM and the

vehicle tilt sensor.

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.

! WARNING

Whenever any maintenance or inspection is made on

the fuel system during which there may be fuel leakage,

there should be no welding, smoking, open flames, etc.,

in the area.

AT THIS POINT

Prior to removing the electric fuel pump, the following

check should be performed to determine that removal is

necessary.

! WARNING

Gasoline may be under pressure. Place an absorbant

towel under the connector to absorb any gasoline spray

when disconnecting.

129

REMOVING

1. Remove the key from the ignition switch.

2. Remove the seat, seat back, and seat base; then dis-

connect 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.

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

fuel pump opening.

INSPECTING

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

sure compressed air.

2. Move the float lever and check for free movement.

The float assembly should return to the lower posi-

tion without force. If not, replace the fuel level sen-

sor assembly.

3. Test the fuel level sensor by connecting a multimeter

(A) to the fuel level sensor leads (B); then select

OHMS. The multimeter should show 5 ohms at full

fuel position (C) and 95 ohms at empty fuel position

(D).

ATV2116



NOTE: If readings are erratic, clean the resistor

wiper and resistor with clean alcohol and retest. If

still not correct, replace the fuel level sensor.

4. To replace the fuel level sensor, use the following

procedure.

A. Disconnect the two-wire connector (A); then

press the fuel level sensor toward the top of the

fuel pump to release it from the mounting slot

(B).

FI460A

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 electri-

cal 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.

! 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.

CAUTION

Take care not to damage the float or float arm or

replacement of the entire assembly will be necessary.

AT THIS POINT

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

proceed to INSTALLING.

130

Troubleshooting

Problem: Starting impaired

Condition Remedy

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

Problem: Idling or low speed impaired

Condition Remedy

1. TPS out of adjustment 1. Adjust TPS

Problem: Medium or high speed impaired

Condition Remedy

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

131

Electrical System

NOTE: Certain components and sensors can be

checked by using the EFI diagnostic system and digi-

tal gauge (see EFI Diagnostic System in this section

for more information).

SPECIAL TOOLS

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

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service 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 periodi-

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

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

age), and/or bulbs.

Battery

NOTE: Preliminary checks may be performed on

this component using the diagnostic mode on the

LCD gauge (see EFI Diagnostic System in this sec-

tion)

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 rec-

ommended for cleaning and maintaining lead-acid batter-

ies. Always read and follow instructions provided with

battery chargers and battery products.

NOTE: Refer to all warnings and cautions provided

with the battery or battery maintainer/charger.

Loss of battery charge may be caused by ambient temper-

ature, ignition OFF current draw, corroded terminals, self

discharge, frequent start/stops, and short engine run

times. Frequent winch usage, snowplowing, extended

low RPM operation, short trips, and high amperage

accessory usage are also reasons for battery discharge.

Maintenance Charging

NOTE: Arctic Cat recommends the use of the CTEK

Multi US 800 or the CTEK Multi US 3300 for battery

maintenance charging. Maintenance charging is

required on all batteries not used for more than two

weeks or as required by battery drain.

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-venti-

lated 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 ter-

minal 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.

800E

Description p/n

Fluke Model 73 Multimeter 0644-191

Fluke Model 77 Multimeter 0644-559

Timing Light 0644-296

MaxiClips 0744-041

Peak Voltage Reading Adapter 0644-307

Test Plug/Code List 0486-219

132



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.

3300A

NOTE: Not using a battery charger with the proper

float maintenance will damage the battery if con-

nected over extended periods.

Charging

NOTE: Arctic Cat recommends the use of the CTEK

Multi US 800 or the CTEK Multi US 3300 for battery

maintenance charging.

1. Be sure the battery and terminals have been cleaned

with a baking soda and water solution.

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

lated 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 ter-

minal of the battery.

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

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

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

Normal Charge Indicator (C) should illuminate on

the upper left portion of the charger.

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

which time the Maintenance Charge Indicator (D)

will illuminate.



NOTE: For optimal charge and performance, leave the

charger connected to the battery for a minimum 1 hour

after the Maintenance Charge Indicator (D) 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 autho-

rized Arctic Cat dealer for further troubleshooting.

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

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 recep-

tacles 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, connec-

tor, or the main wiring harness.

133

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.

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.

RESISTANCE (Switch Connector)

NOTE: The brake pedal must be depressed for

this test.

1. Set the meter selector to the OHMS position.

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

connect the black tester lead to the other black wire.

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

NOTE: Preliminary checks may be performed on

this component using the diagnostic mode on the

LCD gauge (see EFI Diagnostic System in this sec-

tion).

1. Connect the meter leads (selector in OHMS position)

to the sensor terminals.

2. Suspend the sensor and a thermometer in a container

of cooking oil; then heat the oil.

NOTE: Neither the sensor nor the thermometer

should be allowed to touch the bottom of the con-

tainer or inaccurate readings will occur. Use wire

holders to suspend the sensor and thermometer.

3. If the readings are not as indicated, the sensor must

be replaced.

4. Install the sensor and tighten securely; then connect

the leads.

CAUTION

Always disconnect the battery when performing resis-

tance tests to avoid damaging the multimeter.

! WARNING

Wear insulated gloves and safety glasses. Heated oil

can cause severe burns.

MODEL OIL TEMPERATURE OHMS

500 20 °C (68 °F) 2.45k

50 °C (122 °F) 800

80 °C (176 °F) 318

110 °C (212 °F) 142

700 40 °C (104 °F) 1136

100 °C (212 °F) 155

134

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 sec-

tion).

RESISTANCE (Fan Motor Connector)

1. Set the meter selector to the OHMS position.

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

nect the black tester lead to the black wire.

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, con-

nect 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.

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 distribu-

tion module under the operator’s seat.

1. Remove all fuses from the power distribution mod-

ule.

NOTE: To remove a fuse, compress the locking

tabs on either side of the fuse case and lift out.

2411-886

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.

NOTE: Battery voltage will be indicated from only

one side of the fuse holder connector terminal; the

other side will show no voltage.



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

light 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 posi-

tion.

NOTE: If the meter shows no battery voltage,

troubleshoot the battery, switches, power distribu-

tion 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.

! WARNING

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

CAUTION

Always replace a blown fuse with a fuse of the same

type and rating.

135

RESISTANCE

NOTE: For these tests, the meter selector should

be set to the OHMS position.

Primary Winding

1. Connect the red tester lead to the terminal (with the

wire removed); then connect the black tester lead to

ground.

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.

Spark Plug Cap

1. Connect the red tester lead to one end of the cap;

then connect the black tester lead to the other end of

the cap.

AR603D

2. The meter reading must be within specification.

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

replace the spark plug cap.

VOLTAGE

Primary Coil

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

then disconnect the two wires from the coil.

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.

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 Posi-

tion (CKP) Sensor in this section.

OXYGEN (O2) SENSOR

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 tem-

perature (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.

HDX 247

NOTE: For this test, the meter must be in OHMS

position.

5. On the sensor side of connector, connect the black (nega-

tive) 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.

CAUTION

Always disconnect the battery when performing resis-

tance tests to avoid damaging the multimeter.

136

MANIFOLD ABSOLUTE PRESSURE/

INLET AIR TEMPERATURE (MAP/IAT)

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).

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.

4. Connect the MAP/IAT to the harness; then using Maxi-

Clips, 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. Connect the red tester lead to the green/red wire. With

the engine at idle and at room temperature (approxi-

mately 60° F), the meter should read approximately 2.9

DC volts.



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

the sensor.

Speed 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).



NOTE: Prior to testing the speed sensor, inspect the

three-wire connector on the speed sensor for contam-

ination, 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).

KC248A

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).

5. Leave the black tester lead connected; then connect the

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

6. Slowly move the vehicle forward or backward; the meter

must show 0 and approximately 6 volts alternately.



NOTE: If the sensor tests are within specifications,

the LCD gauge must be replaced (see the Steering/

Frame/Controls section).

To replace a speed sensor, use the following procedure.

1. Disconnect the three-wire connector from the speed sen-

sor; 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.

3. Install the new speed sensor into the housing with new

O-ring lightly coated with multi-purpose grease; then

secure the sensor with the cap screw (threads coated with

blue Loctite #242). Tighten securely.

CD071

500

700

137

Electronic Power

Steering (EPS)

Certain models were produced with electronic power steer-

ing. 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-sens-

ing 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.

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).

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.

138

* After correcting the condition, cycle the key switch On-Off-On

Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method

C1301 Over Current EPS internal over-current condition

has been detected

Internal EPS Condition Correct EPS condition*

C1302 Excessive Current Error EPS internal current measurement

error has been detected

Internal EPS Condition Correct EPS condition*

C1303 Torque Sensor Range

Fault

EPS internal torque sensor range con-

dition has been detected

Internal EPS Condition Correct EPS condition*

C1304 Torque Sensor Linearity

Fault

EPS internal torque sensor linearity

condition has been detected

Internal EPS Condition Correct EPS condition*

C1305 Rotor Position Encoder EPS internal rotor position encoder

condition has been detected

Internal EPS Condition Correct EPS condition*

C1306 System Voltage Low EPS battery power low-voltage condi-

tion has been detected

System voltage low (less than 11 VDC at the

EPS). Wire harness issue, faulty voltage regu-

lator, weak battery or loose battery terminals.

EPS will auto-recover when the bat-

tery supply returns to normal

C1307 System Voltage High EPS battery power over-voltage condi-

tion has been detected

System voltage high (more than 16 VDC at

the EPS). Wire harness issue, faulty voltage

regulator or loose battery terminals.

EPS will auto-recover when the bat-

tery supply returns to normal

C1308 Temperature Above

110° C

EPS internal 110o C over-temp condi-

tion has been detected

Clean the EPS housing and cooling fins. EPS will auto-recover when internal

temperature drops below 105° C

C1309 Temperature Above

120° C

EPS internal 120o C over-temp condi-

tion has been detected

Clean the EPS housing and cooling fins. EPS will auto-recover when internal

temperature drops below 115° C

C1310 Vehicle Speed High Vehicle speed signal received by the

EPS exceeds the maximum speed

specification

Intermittent main harness wires, defective

speed-sensor, or intermittent speed sensor

wires.

EPS will auto-recover when the vehi-

cle speed signal drops below the

maximum speed specification

C1311 Vehicle Speed Low Vehicle speed signal received by the

EPS is zero or missing

Broken main harness wires, defective speed-

sensor, or broken speed sensor wires.

EPS will auto-recover when the vehi-

cle speed signal returns to normal

C1312 Vehicle Speed Faulty Vehicle speed CAN signal received by

the EPS incorrect or missing

Broken main harness CAN wires, defective

speed-sensor, or broken speed sensor wires.

EPS will auto-recover when the vehi-

cle speed signal returns to normal

C1313 Engine RPM High Engine RPM signal received by the

EPS exceeds the maximum RPM

specification

Intermittent main harness RPM wires, inter-

mittent voltage regulator, intermittent ACG sta-

tor wires.

EPS will auto-recover when engine

RPM signal drops below the maxi-

mum RPM specification

C1314 Engine RPM Low Engine RPM signal received by the

EPS suddenly dropped below 500

RPM

Handlebar switch in the "OFF" position, bro-

ken main harness RPM wires, defect voltage

regulator, broken ACG stator wires.

EPS will auto-recover when engine

RPM signal returns to normal

C1315 Engine RPM Faulty Engine RPM CAN signal received by

the EPS incorrect or missing

Broken main harness CAN wires or defective

ECM.

EPS will auto-recover when engine

RPM signal returns to normal

C1316 EEPROM Error EPS internal memory error has been

detected

Internal EPS condition Correct EPS condition*

C1317 CAN Bus Error The EPS has lost CAN communication

with the EFI ECM

Broken CAN wires in the main harness. EFI

ECM connector has been disconnected.

Correct EPS condition*

C1318 Internal CRC Error EPS internal CRC calculation condition

has been detected

EPS reflash has failed. Battery power was

lost, or the keyswitch was turned off, during

EPS reflash programming.

EPS must be reprogrammed

C1319 Boot Counter Exceeded EPS internal application code condi-

tion has been detected

Intermittent power has prevented a successful

application code launch.

Correct EPS power condition*

C1320 Incorrect Vehicle

Speed-to-RPM Ratio

Vehicle speed signal received by the

EPS exceeds 10 MPH, but the engine

RPM signal less than 500 RPM

Intermittent or broken main harness RPM

wires, intermittent voltage regulator, intermit-

tent or broken ACG stator wires.

Correct EPS condition*

C1321 Vehicle Speed Erratic Vehicle speed signal received by the

EPS changing at an unrealistic rate

Intermittent main harness, intermittent speed

sensor, dirty speed senor or trigger wheel.

Correct EPS vehicle speed signal

condition*

C1322 Engine RPM Lost Engine RPM signal received by the

EPS exceeds 500 RPM and then is

zero or missing

Handlebar switch in the "OFF" position, bro-

ken main harness RPM wires, defect voltage

regulator, broken ACG stator wires.

EPS will auto-recover when engine

RPM signal returns to normal

C1323 "EPS OFF" Gauge Dis-

play

Battery power has been applied to the

EPS for more than 5-minutes, but no

engine RPM signal has been detected

The EPS has been automatically disabled,

after 5-minutes of inactivity, to conserve bat-

tery power.

EPS will auto-recover when engine

is started or the keyswitch is cycled

On-Off-On

C1324 Loss of CAN communi-

cation with EPS unit

The gauge has lost CAN communica-

tion with the EPS

Broken CAN wires in the main harness or dis-

connected EPS. This is not an EPS generated

DTC; gauge DTC display only.

Gauge DTC display will clear when

the EPS-to-gauge CAN communica-

tion is restored.

C1325 Dual Loss EPS loss of both the vehicle speed and

the engine RPM signals has been

detected

Handlebar switch in the "OFF" position, the

engine stalled (keyswitch "ON"), broken har-

ness wires, loss of CAN data signal.

EPS will auto-recover when either

the vehicle speed or engine RPM

signal is restored.

C1326 Rotor Position Encoder EPS internal rotor position encoder

variance condition has been detected

Internal EPS Condition Correct EPS condition*

C1327 Voltage Converter Error

(Low)

EPS internal voltage converter low-

voltage condition has been detected

Internal EPS Condition Correct EPS condition*

C1328 Voltage Converter Error

(High)

EPS internal voltage converter over-

voltage condition has been detected

Internal EPS Condition Correct EPS condition*

C1329 Internal Data Error EPS internal preloaded data condition

has been detected

Internal EPS Condition EPS must be reprogrammed

139

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 deacti-

vate the EPS and display the code. Turn the Ignition

Key Switch OFF and back to ON to reset and reacti-

vate 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 4-

pin 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 har-

ness (black meter lead to BLK and red meter lead to

ORG/BRN).With the ignition switch to the ON posi-

tion, 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 sec-

tion).

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 acces-

sory 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 con-

nect the black meter lead to ground.

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.

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 bat-

tery 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 volt-

age 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 volt-

age, 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 head-

light 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 dis-

connect 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.

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.

140

PR566A

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.



NOTE: If the meter does not show voltages accord-

ing 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 trans-

mission 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.

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.

7. Depress the reverse override switch. The meter must

show approximately 5 DC volts.

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 selec-

tor actuator on the frame to the right of the differen-

tial; then connect the red meter lead to the orange

wire using a MaxiClip.

PR293

Connect the black lead to the black wire using a Maxi-

Clip; then select 2WD on the drive select switch.

2WD 4WD DIFFERENTIAL LOCK

A to D <1 ohm A to D <1 ohm A to D <1 ohm

C to E <1 ohm C to E <1 ohm C to E <1 ohm

A to B Open A to B <1 ohm A to B <1 ohm

A to C Open A to C Open A to C <1 ohm

A to E Open A to B <1 ohm A to C <1 ohm

WIRE COLOR 2WD 4WD DIFFERENTIAL LOCK

Black to Orange 12.0 DC Volts 12.0 DC Volts 12.0 DC Volts

Black to White/

Green

11.5 DC Volts 0 DC Volts 0 DC Volts

Black to White/

Red

11.5 DC Volts 11.5 DC Volts 0 DC Volts

141

PR295

NOTE: The black tester lead can remain con-

nected 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 battery voltage is not shown, trouble-

shoot 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 sec-

tion).

VOLTAGE (AC Generator - Regulated

Output)

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

2. Connect the red tester lead to the positive battery

post; then connect the black tester lead to the nega-

tive battery post.

3. With the 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.

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.

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

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)

1. Set the meter selector to OHMS position.

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

three tests.

MODEL RPM

500 3000

700 5000

CAUTION

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

onds.

CAUTION

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

onds.

CAUTION

Always disconnect the battery when performing resis-

tance tests to avoid damaging the multimeter.

142

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.

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.

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 sec-

tion).

NOTE: The starter motor is not a serviceable

component. If the starter is defective, it must be

replaced.

REMOVING

1. Disconnect the battery.

2. Remove the nut securing the positive cable to the starter;

then remove the cable from the starter.

3. Remove the two cap screws securing the starter 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.



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

tion, 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.

AR607D

NOTE: If the meter showed battery voltage but

the starter did not operate or operated slowly,

inspect battery voltage (at the battery), starter con-

dition, 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 ter-

minal; then connect the black tester lead to the starter

cable connection on the starter relay. The meter must

show battery voltage.

PR296

CAUTION

Always disconnect the negative battery cable from the

battery first; then disconnect the positive cable.

143

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 multi-

meter. 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.

PR297A

5. Depress the starter button and observe the multimeter.

NOTE: If battery voltage is indicated, replace the

starter relay.

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; how-

ever, if the ECM is suspected, substitute another ECM to ver-

ify the suspected one is defective.

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 dif-

ferent model as the system will not allow it to start.

Error codes can be cleared by following the procedures

located in the EFI Diagnostic System sub-section in this

section.

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 tempera-

tures; 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 regu-

lator is faulty or a battery connection is loose or cor-

roded. Clean and tighten battery connections or

replace the regulator/rectifier. If voltage does not rise,

replace the regulator/rectifier.

Headlights

The connectors are the four 2-prong ones secured to the

headlight bulbs (two on each side).

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.

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.

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.

144

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.

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 junc-

ture 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, wir-

ing harness, or connectors.

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 ten-

sion 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.

If ignition timing cannot be verified, the rotor may be dam-

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

be bent or damaged, or the 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 momen-

tarily followed by COOL.

EFI002A

NOTE: The display on the gauge will display in

SAE (speedometer in MPH mode) or Metric (speed-

ometer in km/h mode), For example to read tem-

perature 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.

EFI004

NOTE: The gauge can be utilized dynamically

(engine running/vehicle moving) or statically

(engine/vehicle stopped).

145

Examples of Static checks: Battery voltage, fuel gauge/

sensor, and TPS (0% @ closed throttle, 95-100% @

WOT).

EFI007

Examples of Dynamic checks: Battery charging, coolant

temperature including fans ON/OFF (see below), MAP/

IAT, tachometer, and speedometer signal.

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

EFI 003

Display: Engine coolant temperature as measured by the

ECT sensor.

DTC: P0116, P0117, P0118, P0119

Usage: Monitor coolant temperature to verify the follow-

ing.

1. ECT sensor signal

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

EFI010

Display: Fuel level signal from the fuel level sensor (mea-

sured in ohms).

DTC: C1400, C1401, C1402

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

EFI009

Display: Engine RPM

DTC: P0336, P0337, P0339

Usage: Verify engine speed signal from the following.

1. CKP (crankshaft position) sensor to ECM

2. ECM (CAN) signal to gauge (tachometer)

146

3. ECM (CAN) signal to EPS

Speed (SPd) Diagnostic Mode

EFI008

Display: vehicle speed signal.

DTC: P0500

Usage: verify speedometer sensor signal from the follow-

ing.

1. Speed sensor to ECM.

2. ECM (CAN) signal to gauge (speedometer/odome-

ter).

3. ECM (CAN) signal to EPS unit.

TPS (tPS) Diagnostic Mode

EFI007

Display: % of TPS (0% closed, 95-100% WOT).

DTC: P0121, P0122, P0123

Usage: Verify TPS signal and adjust throttle cable.

MAP (bArO) Diagnostic Mode

EFI006

Display: MAP in millibars (1013 millibar = 29.92 in.

mercury).

DTC: P0107, P0108

Usage: Verify barometric pressure signal correct.

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 milli-

bars) The gauge should be reading very close to

1015.

Inlet Air Temperature (AIr)

Diagnostic Mode

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 read-

ings will be higher than outside air temperature

due to engine and engine compartment heat as

well as intake manifold heating.

147

Battery (bAtt) Diagnostic Mode

EFI004

Display: System DC voltage.

DTC: P0562, P0563, P2531, P2532

Usage: Verify system voltage under following condi-

tions.

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).

3. Battery voltage with electrical accessories operating,

engine idling (13.5 VDC or greater).

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-of-

tolerance 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

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” pre-

fix denotes a loss of communication with the

gauge.

NOTE: Normal malfunction codes are cleared from

the LCD when the component is replaced or the mal-

function is corrected; however, intermittent codes

must be cleared as noted in the code chart.

Code Fault Description Possible Cause Fault Recovery Method

C0063 Tilt Sensor Circuit High Sensor or interconnect harness shorted to battery power Correct condition*

C0064 Tilt Sensor Circuit Low/SG/Open Sensor or interconnect harness open or shorted to chassis ground Correct condition*

P0030 O2 Heater Intermittent/Open Heater or interconnect harness intermittent or open Correct condition*

P0031 O2 Heater Low/SG Heater or interconnect harness shorted to chassis ground Correct condition*

P0032 O2 Heater High/SP Heater or interconnect harness shorted to battery power Correct condition*

P0107 MAP Sensor Circuit Low/SG/Open Sensor or interconnect harness shorted to chassis ground Correct condition*

P0108 MAP Sensor Circuit High/SP Sensor or interconnect harness shorted to battery power Correct condition*

P0112 IAT Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition*

P0113 IAT Sensor Circuit High/Open Sensor or interconnect harness open or shorted to battery power Correct condition*

P0114 IAT Sensor Circuit Intermittent Sensor or interconnect harness intermittent Correct condition*

P0116 ECT Sensor Circuit Range/Performance Sensor producing an out-of-range voltage Correct condition*

P0117 ECT Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition*

P0118 ECT Sensor Circuit High/Open/SP Sensor or interconnect harness open or shorted to battery power Correct condition*

P0119 ECT Sensor Circuit Intermittent Sensor or interconnect harness intermittent Correct condition*

P0121 TPS Range/Performance Sensor producing an out-of-range voltage Correct condition*

P0122 TPS Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition*

P0123 TPS Circuit High Sensor or interconnect harness open or shorted to battery power Correct condition*

P0130 O2 Sensor Intermittent/Open Sensor or interconnect harness intermittent or open Correct condition*

P0131 O2 Sensor Low/SG or Air-Leak Sensor or interconnect harness shorted to chassis ground or an air-

leak exists

Correct condition*

P0132 O2 Sensor High/SP Sensor or interconnect harness shorted to battery power Correct condition*

P0171 O2 Feedback Below Minimum Correction Low fuel rail pressure, dirty fuel filter, or dirty injectors Correct condition*

P0172 O2 Feedback Exceeds Maximum Correc-

tion

Excessive fuel rail pressure, MAP or temp sensors out-of-spec Correct condition*

P0219 Engine Over-Speed Condition Engine speed (RPM) has exceeded the ECM over-speed setpoint/

limit

Reduce engine speed

P0231 Fuel Pump Relay Circuit Low/SG/Open Relay has been removed or interconnect harness shorted to chassis

ground

Correct condition*

P0232 Fuel Pump Relay Circuit High Relay or interconnect harness shorted to battery power Correct condition*

P0233 Fuel Pump Relay Circuit Relay circuit erratic or intermittent Correct condition*

P0261 Rear Cylinder Fuel injector Circuit Low/SG Injector or interconnect harness shorted to chassis ground Correct condition**

P0262 Rear Cylinder Fuel injector Circuit High Injector or interconnect harness shorted to battery power Correct condition**

P0263 Rear Cylinder Fuel injector Balance/Open Injector has been disconnected or interconnect harness open Correct condition**

P0264 Front Cylinder Fuel injector Circuit Low/SG Injector or interconnect harness shorted to chassis ground Correct condition**

P0265 Front Cylinder Fuel injector Circuit High Injector or interconnect harness shorted to battery power Correct condition**

P0266 Front Cylinder Fuel injector Balance/Open Injector has been disconnected or interconnect harness open Correct condition**

P0336 Crankshaft Angle Sensor Synchronization Sensor or interconnect harness intermittent Correct condition**

148

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

* After correcting the condition, cycle the key switch On-Off-

**After correcting the condition, cycle the key switch On-Off-

On, start the engine, then cycle the key switch On-Off-

On.

P0337 Crankshaft Angle Sensor Circuit/SG Sensor or interconnect harness shorted to chassis ground Correct condition**

P0339 Crankshaft Angle Sensor Intermittent/

Erratic

Sensor or interconnect harness intermittent Correct condition**

P0340 Camshaft Angle Sensor Synchronization Sensor or interconnect harness intermittent Correct condition**

P0341 Camshaft Angle Sensor Circuit/SG Sensor or interconnect harness shorted to chassis ground Correct condition**

P0342 Camshaft Angle Sensor Intermittent/Erratic Sensor or interconnect harness intermittent Correct condition**

P0480 Fan-Primary/Right Relay Control Circuit Relay erratic or intermittent Correct condition*

P0481 Fan-Secondary/Left Relay Control Circuit

High

Relay or interconnect harness shorted to battery power Correct condition*

P0482 Fan-Secondary/Left Relay Control Circuit

Low/SG/Open

Secondary fan fuse has blown, the secondary fan relay has been

removed or interconnect harness shorted to chassis ground

Correct condition*

P0483 Fan-Secondary/Left Relay Control Circuit Relay erratic or intermittent Correct condition*

P0484 Fan-Primary/Right Relay Control Circuit

High

Relay or interconnect harness shorted to battery power Correct condition*

P0485 Fan-Primary/Right Relay Control Circuit

Low/SG/Open

Primary fan fuse has blown, the primary fan relay has been removed

or interconnect harness shorted to chassis ground

Correct condition*

P0500 Vehicle Speed-Sensor 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

power

Correct condition*

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

high

Correct condition*

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

erratic or intermittent

Correct condition*

P0616 Starter Relay Circuit Low Start switch/button, starter relay or interconnect harness intermittent

or shorted to chassis ground

Correct condition*

P0617 Starter Relay Circuit High Start switch/button, starter relay or interconnect harness intermittent

or shorted to battery power

Correct condition*

P0630 VIN Not Programmed or Incompatible Verify the LCD gauge and ECM part numbers are correct for the vehi-

cle model number and VIN

Correct gauge and ECM

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/

Open

Coil or interconnect harness open or shorted to chassis ground Correct condition**

P2301 Rear Ignition Coil Primary Circuit High Coil or interconnect harness shorted to battery power Correct condition**

P2303 Front Ignition Coil Primary Circuit Low/

Open

Coil or interconnect harness open or shorted to chassis ground Correct condition**

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

high

Correct condition*

U0155 LCD Gauge to EFI ECM CAN Communica-

tion Lost

Gauge CAN circuit or interconnect harness intermittent or has failed Correct condition*

U1000 Vehicle Not Registered or Invalid PIN

Entered

An invalid registration PIN has been entered Enter the correct registra-

tion PIN*

U1001 Vehicle Not Registered and Vehicle Limits

Enabled

An invalid registration PIN has been entered Enter the correct registra-

tion PIN*

FUEL OFF Tilt Sensor Activation Code Sensor has been activated Restore the vehicle chassis

to an upright position*

Code Fault Description Possible Cause Fault Recovery Method

149

Tilt Sensor

SUPPLY VOLTAGE

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

then select DC Voltage on the multimeter and con-

nect the red tester lead to the orange wire (C) and the

black tester lead to the black wire (A).

CD706A

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

multimeter should read battery voltage. If battery

voltage is not indicated, check the 30-amp fuse 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.

CD706B

OUTPUT VOLTAGE

NOTE: Needle adapters will be required on the

multimeter leads as the following tests are made

with the sensor connected.

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

remove the right-side mounting screw securing the

sensor to the rear frame.

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).

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.

! WARNING

Incorrect installation of the tilt sensor could cause sud-

den loss of engine power which could result in loss of

vehicle control resulting in injury or death.

CAUTION

Do not drop the tilt sensor as shock can damage the

internal mechanism.

150

CD709

NOTE: When replacing the sensor after testing,

make sure the arrow marking is directed up.

CD705A

Throttle Position Sensor

(TPS)

NOTE: Preliminary checks may be performed on

this component using the diagnostic mode on the

LCD gauge (see EFI Diagnostic System in this sec-

tion).

TESTING

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

the three-wire TPS connector plug.

NOTE: Prior to testing the TPS, inspect the three-

wire plug connector on the main harness and the

three-pin plug on the TPS for contamination, broken

pins, and/or corrosion.

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.

2. Connect the TPS Multi-Analyzer Harness connector

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

Analyzer Tool.

FI672

3. On the 500 using a multimeter, connect the black tes-

ter 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.

FI673A

4. On the 700 using a multimeter, connect the black tes-

ter 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.

FI676A

151

Troubleshooting

Problem: Spark absent or weak

Condition Remedy

1. Ignition coil defective

2. Spark plug(s) defective

3. CKP sensor defective

4. ECM defective

1. Replace ignition coil

2. Replace plug(s)

3. Replace CKP sensor

4. Replace ECM

Problem: Spark plug fouled with carbon

Condition Remedy

1. Gasoline incorrect

2. Air cleaner element dirty

3. Spark plug(s) incorrect (too cold)

4. Valve seals cracked - missing

5. Oil rings worn - broken

1. Change to correct gasoline

2. Clean element

3. Replace plug(s)

4. Replace seals

5. Replace rings

Problem: Spark plug electrodes overheat or burn

Condition Remedy

1. Spark plug(s) incorrect (too hot)

2. Engine overheats

3. Spark plug(s) loose

1. Replace plug(s)

2. Service cooling system

3. Tighten plug(s)

Problem: Battery does not charge

Condition Remedy

1. Lead wires/connections shorted - loose - open

2. Stator coils shorted - grounded - open

3. Regulator/rectifier shorted

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. Lead wires shorted - open - loose (at terminals)

2. Stator coils grounded - open

3. Regulator/rectifier defective

4. Cell plates (battery) defective

1. Repair - tighten lead wires

2. Replace stator coils

3. Replace regulator/rectifier

4. Replace battery

Problem: Magneto overcharges

Condition Remedy

1. Battery short circuited

2. Regulator/rectifier defective

3. Regulator/rectifier poorly grounded

1. Replace battery

2. Replace regulator/rectifier

3. Clean - tighten ground connection

Problem: Charging unstable

Condition Remedy

1. Lead wire intermittently shorting

2. Magneto internally shorted

3. Regulator/rectifier defective

1. Replace lead wire

2. Replace stator coil

3. Replace regulator/rectifier

Problem: Starter does not engage

Condition Remedy

1. Battery charge low

2. Switch contacts defective

3. Starter motor brushes not seating

4. Starter relay defective

5. Wiring connections loose - disconnected

6. Start-in-gear/neutral relay defective

1. Recharge - replace battery

2. Replace switch

3. Replace starter

4. Replace relay

5. Connect - tighten - repair connections

6. 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

1. Replace battery

2. Charge battery

Problem: Battery discharges too rapidly

Condition Remedy

1. Charging system (charging operation) not set properly

2. Cell plates overcharged - damaged

3. Battery short-circuited

4. Electrical load too high

1. Check AC generator - regulator/rectifier - circuit connections

2. Replace battery - correct charging system

3. Replace battery

4. Reduce load

Problem: Battery polarity reversed

Condition Remedy

1. Battery incorrectly connected 1. Reverse connections - replace battery

152

Drive System

GENERAL INFORMATION

All gear cases are tagged beneath a cover bolt. This tag is

marked with a production date code, sequence code, and

a ratio code. 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.

NOTE: Never reuse a lock nut. Once a lock nut

has been removed, it must be replaced with a new

lock nut.

SPECIAL TOOLS

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

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Department.

Front Drive Actuator

NOTE: The actuator is not a serviceable compo-

nent. If it is defective, it must be replaced.

NOTE: The actuator will operate only when the

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.

REMOVING

1. Select LOCK on the drive select switch; then discon-

nect 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.

PR189A

3. Remove the mounting cap screw from above the

actuator on the suspension side.

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.

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.

Size New Housing Reassembled

Housing

M6 (Torx T-30 Recess) 9 ft-lb 8 ft-lb

M8 (Torx T-40 Recess) 28 ft-lb 23 ft-lb

Description p/n

Backlash Measuring Tool (24-Spline Axle) 0544-010

Backlash Measuring Tool (27-Spline Axle) 0544-011

CV Boot Clamp Tool 0444-120

Internal Hex Socket 0444-104

Pinion Gear/Shaft Removal Tool 0444-127

Gear Case Seal Installer Tool 0444-224

U-Joint Separator Tool 0444-128

153

NOTE: Make sure to properly align the differential

lock actuator lever with the hole in the differential

lock plunger.

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.

GC001

4. Loosen the front cap screw; then tighten the cap

screw on the driveshaft side.

AG926

NOTE: It is important to tighten this cap screw while

the others are loose to ensure proper seating of the

actuator.

5. Tighten the remaining cap screws; then connect the

electrical plug to the main harness.

6. Turn the ignition switch to the ON position and

check the operation by shifting the select switch sev-

eral times.

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.

2. Remove the drain plug and drain the gear lubricant

into a drain pan; then install the plug and tighten to

45 in.-lb.

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.

! WARNING

Make sure the vehicle is solidly supported on the jack

stands to avoid injury.

154

PR264A

7. Disconnect the front drive actuator connector from

the main harness.

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.

PR193

9. Pull the steering knuckle away from the axle.

PR222

10. Support the axle to not allow it to drop or hang.

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.

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.

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.

CAUTION

The axle must be supported. If the axle is allowed to

drop or hang, damage to the inner CV joint may occur.

155

PR205A

14. Remove the upper differential mounting cap screw.

Account for a lock nut and two washers.

CD016

15. Free the differential assembly from the frame mount-

ings; 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.

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 assem-

bling purposes.

GC015

CD106

3. Remove the snap rings from the input shaft; then

remove the input shaft from the pinion housing.

GC009A

4. Using a seal removal tool, remove the input shaft

seal. Account for a spacer.

GC010

156

5. Remove the snap ring securing the input shaft bear-

ing; then place the pinion housing in a press and

remove the bearing.

GC011

AF984

KX219

Assembling Input Shaft

1. Place the pinion housing in a press and install the

input shaft bearing. Secure the bearing with the

existing snap ring making sure the sharp edge of the

snap ring faces to the outside.

GC012

GC011

2. Install the input shaft seal making sure it is fully

seated in the edge of the housing.

GC014

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.

157

GC009A

5. Place the pinion housing with new gasket onto the

differential housing; then secure with existing cap

screws. Tighten to 23 ft-lb.

NOTE: If a new differential housing is being

installed, tighten the cap screws to 28 ft-lb.

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).

GC015

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.

GC003

3. Using a plastic mallet, tap lightly to remove the dif-

ferential cover. Account for an O-ring.

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.

158

KX175

5. Remove the left differential bearing flange assembly

and account for a shim. Mark the shim as left-side.

KX177

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.

KX179

KX181

Disassembling Pinion Gear

1. Remove the internal snap ring securing the pinion

bearing in the housing.

WC430

2. Using the Pinion Gear/Shaft Removal Tool and a

hammer, remove the pinion gear from the gear case

housing.

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.

159

CC879

4. Remove any reusable parts from the gear case hous-

ing; then discard the housing and lock collar.

Assembling Pinion Gear

1. Install the bearing onto the pinion shaft. Install the

pinion shaft collar.

CC882

CC883

2. Place the pinion assembly in a bearing puller; then

install the bearing using a press.

CC884

3. Using a propane torch, heat the gear case housing to

approximately 200° F; then install the pinion assem-

bly.

4. Install the internal snap ring with the sharp side

directed away from the bearing.

WC429

Shimming Procedure/Shim Selection

It is very important to adjust bevel gears for the proper

running tolerances. Gear life and gear noise are greatly

affected by these tolerances; therefore, it is very impor-

tant to properly adjust any gear set prior to final assem-

bly.

The following procedure can be used on both front differ-

ential or rear drive gear case.

Case-Side Shims (Backlash)

p/n mm in.

0402-405 1.3 0.051

0402-406 1.4 0.055

0402-407 1.5 0.059

0402-408 1.6 0.063

0402-409 1.7 0.067

Cover-Side Shims (Ring Gear End-Play)

p/n mm 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

160

NOTE: All bearings must be installed in the gear

case and the pinion properly installed before pro-

ceeding.

Backlash

NOTE: Always set backlash prior to any other shim-

ming.

1. Install the existing shim or a 0.051-0.055-in. shim on

the gear case side of the ring gear assembly.

GC031A

2. Install the ring gear with shim in the gear case; then

while holding the pinion stationary, rock the ring

gear forward and back to determine if any backlash

exists. If no backlash exists, install a thicker shim

and recheck.

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 bear-

ing flange is completely seated in the cover.

GC032A

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.

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.

GC040

161

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.

NOTE: Higher backlash settings usually result in

quieter gear operation.

GC037A

Ring Gear End-Play

After correcting backlash, ring gear end-play can be

adjusted. To adjust end-play, use the following proce-

dure.

1. Secure the gear case in a holding fixture with the

cover side up; then install a dial indicator contacting

the ring gear axle flange.

GC035

2. Zero the dial indicator; then push the ring gear

toward the dial indicator and release. End-play

should be 0.004-0.008 in.

3. To increase end-play, decrease the shim thickness.

To decrease end-play, increase the shim thickness.



NOTE: Once proper backlash and end play are estab-

lished, the gear case can be assembled.

Assembling Differential Assembly

1. With the pinion gear and new bearings installed, place

the selected (backlash) shim on the gear case side of

the ring gear with the chamfered side toward the ring

gear; then install into gear case/differential housing.

GC031A

GC020

2. Place the selected (end-play) shim, chamfered side

toward the gear, onto the cover side of the ring gear.

GC036B

NOTE: The spider and ring gear assembly must be

replaced as a complete unit.

162

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

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.

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.

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.

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.

CD103

163

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.

CC899

NOTE: Prior to installing the seal, apply High-Per-

formance #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.

CF278

3. Repeat steps 1-2 for the opposite side.

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.

PR205A

3. Tighten the nuts to 38 ft-lb.

4. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lubri-

cant 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.

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.

PR201

CAUTION

Make sure the tool is free of nicks or sharp edges or

damage to the seal may occur.

164

PR193

8. Secure the lower shock eyelets with cap screws and

lock nuts. Tighten to 20 ft-lb.

AF897D

9. Install the brake calipers. Secure with new “patch-

lock” cap screws tightened to 20 ft-lb.

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.

PR256

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.

2. Place the transmission in park; then remove the

wheels.

3. Remove the cotter pins securing the axle nuts; then

remove the nuts.

KX041

4. Slide the hub out of the knuckle and set aside.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

165

PR221

5. Remove the cap screw and lock nut securing the

knuckle to the upper A-arm. Discard the lock nut.

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.

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.

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 com-

ponents to determine if any service or replacement is

necessary.

1. Using a clean towel, wipe away any oil or grease

from the axle components.

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

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

166

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

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 tight-

ened 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 steer-

ing 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.

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.

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 rear-

most 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.

167

PR207

RING GEAR/THRUST BUTTON

Removing

1. Remove the cap screws securing the gear case cover

to the gear case; then remove the ring gear.

2. Remove the thrust button from the gear case cover

(left-hand threads). Account for a shim.

Inspecting

1. Inspect the ring gear for excessive wear, missing or

chipped teeth, or discoloration.

2. Inspect the thrust button for excessive wear or dis-

coloration.

3. Inspect the bearings for discoloration, roughness, or

excessive wear.

Installing/Shimming

NOTE: Ring gear 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).

GC057A

2. Place the ring gear with selected shim into the cover

and measure the ring gear to thrust button clearance

with a thickness gauge. Clearance should be 0.002-

0.004 in.

GC058A

3. If clearance is as specified, remove the ring gear and

thrust button; then place a drop of red Loctite #271

on the threads and tighten to 8 ft-lb (left-hand

threads).

4. If clearance is not as specified, repeat steps 1 and 2

using thicker shim (clearance too great) or thinner

shim (clearance too small) until correct specification

is reached.

REAR DRIVE INPUT SHAFT/

HOUSING

Removing/Disassembling

1. Remove the cap screws securing the rear drive input

shaft/housing to the rear gear case; then remove the

input housing assembly.

GZ183

2. Remove the input shaft from the input housing; then

remove the oil seal.

GZ180

AT THIS POINT

For servicing the input shaft, pinion gear, needle bear-

ing, ring gear, and axle seal, see Front Differential in

this section.

168

GZ182A

3. Remove the snap ring retaining the input bearing and

using an appropriate bearing driver, press the bearing

from the housing.

GZ184A

Cleaning and Inspecting

1. Wash all parts in parts cleaning solvent and dry 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).

GZ184

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.

GZ182A

3. Apply grease to the lips of the oil seal; then install

the input shaft into the input bearing and housing.

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.

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.

! WARNING

Always wear safety glasses when working with com-

pressed air.

AT THIS POINT

For servicing the input shaft, pinion gear, needle bear-

ing, and axle seal, see Front Differential in this section.

169

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 “patch-

lock” cap screws to 20 ft-lb.

6. Fill the gear case with the appropriate lubricant.

Hub

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.

2. Remove the cotter pin from the axle.

NOTE: During assembly, new cotter pins should

be installed.

PR257

3. Remove the hub nut securing the hub.

4. Remove the brake caliper (front only).

PR243A

5. Remove the hub assembly.

6. Remove the four cap screws securing the brake disc.

PR254A

CLEANING AND INSPECTING

1. Clean all hub components.

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.

PR250

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

170

3. Using a socket and ratchet handle, tighten the nut

until the stud is fully drawn into the hub.

PR252A

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.

PR254B

3. Install the hub assembly onto the axle; then place the

transmission in park.

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.

PR258

5. Secure the brake calipers to the knuckle with two

new “patch-lock” cap screws tightened to 20 ft-lb.

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.

Hydraulic Brake Caliper

REMOVING/DISASSEMBLING

1. Secure the vehicle on a support stand to elevate the

wheel; then remove the wheel.

2. Drain the brake fluid from the caliper, hose, and

master cylinder through the bleed screw by pumping

the brake pedal.

! 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 con-

trol causing severe injury or death.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port 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.

171

PR235

NOTE: Whenever brake components are removed,

disassembled, or repaired where brake fluid is

exposed to air, drain all fluid and replace with new

DOT 4 brake fluid from an unopened container. Brake

fluid readily absorbs moisture from the air signifi-

cantly lowering the boiling point. This increases the

chance of vapor lock reducing braking power and

increasing stopping distance.

3. Remove the brake hose from the caliper and close

the bleed screw; then remove the caliper.

4. Compress the caliper holder against the caliper

(opposite the O-ring side) and remove the outer

brake pad; then remove the inner brake pad.

NOTE: If brake pads are to be returned to service,

do not allow brake fluid to contaminate them.

PR237A

PR238

5. Remove the caliper holder from the caliper and dis-

card the O-ring.

PR239B

NOTE: The O-ring is used for shipping purposes

and provides no function in operation.

6. Cover the piston end of the housing with a shop

towel; then keeping fingers clear of piston travel,

apply compressed air to the fluid port to blow the

piston free of the housing. Account for two seal rings

in the housing.

PR713A

CAUTION

Brake fluid is highly corrosive. Do not spill brake fluid

on any surface of the vehicle and do not reuse brake

fluid.

172

PR715

7. Using an appropriate seal removal tool, carefully

remove the seals from the brake caliper housing; then

remove four O-rings from the brake caliper housing

noting the location of the different sized O-rings. Dis-

card all seals, O-rings, and crush washers.

CLEANING AND INSPECTING

1. Clean all caliper components (except the brake pads)

with DOT 4 brake fluid. Do not wipe dry.

2. Inspect the brake pads for damage and excessive

wear.

NOTE: For measuring brake pads, see the Peri-

odic Maintenance - Hydraulic Brake System.

3. Inspect the brake caliper housings for scoring in the

piston bores, chipped seal ring grooves, or signs of

corrosion or discoloration.

4. Inspect the piston surface for scoring, discoloration,

or evidence of binding or galling.

5. Inspect the caliper holder for wear or bending.

ASSEMBLING/INSTALLING

1. Install new seals into the brake caliper housing and

apply a liberal amount of DOT 4 brake fluid to the

cylinder bore of the housing, seals, and brake piston.

PR715

PR717A

2. Press the piston into the caliper housing using hand

pressure only. Completely seat the piston; then wipe

off any excessive brake fluid.

PR711A

PR712

3. Apply high-temperature silicone grease (supplied

with the O-ring kit) to the inside of the caliper holder

bores and O-rings; then install the four O-rings into

the caliper.

PR719C

! WARNING

Make sure to hold the towel firmly in place or the piston

could be ejected from the housing causing injury.

CAUTION

Make sure the seals are properly in place and did not

twist or roll during installation.

173

4. Install the caliper onto the caliper holder making sure

the caliper and holder are correctly oriented.

NOTE: It is very important to apply silicone

grease to the O-rings and caliper bores prior to

assembly.

PR239C

5. Making sure brake fluid does not contact the brake

pads, compress the caliper holder toward the caliper and

install the inner brake pad; then install the outer pad.

PR238

PR239

6. Place the brake caliper assembly into position and

secure with new “patch-lock” cap screws. Tighten

the caliper to 20 ft-lb.

7. Place a new crush washer on each side of the brake hose

fitting and install it on the caliper. Tighten to 20 ft-lb.

8. Fill the reservoir; then bleed the brake system (see

Periodic Maintenance - Hydraulic Brake System).

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 ver-

ify brake operation.

MASTER CYLINDER ASSEMBLY

NOTE: The master cylinder is a non-serviceable

component; it must be replaced as an assembly.

Removing

1. Slide a piece of flexible tubing over one of the wheel

bleeder valves and direct the other end into a con-

tainer. Remove the reservoir cover; then open the

bleeder valve. Allow the brake fluid to drain until the

reservoir is empty.

AF637D

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.

PR338

CAUTION

If brake pads become contaminated with brake fluid, they

must be thoroughly cleaned with brake cleaning solvent

or replaced with new pads. Failure to do so will result in

reduced braking and premature brake pad failure.

! WARNING

Never use brake fluid from an open container or reuse

brake fluid. Moisture-contaminated brake fluid could

cause vapor build-up (expansion) during hard braking

resulting in greatly increased stopping distance or loss

of control leading to injury or death.

174

PR336

3. Remove the oil bolt securing the banjo-fittings to the

master cylinder; then remove the master cylinder.

Discard the three crush washers.

Inspecting

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-fit-

tings 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 Mainte-

nance section).

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 compo-

nents prior to removing.

3. Remove the cap screws securing the driveshaft

flange to the output flange; then remove the drive-

shaft.

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.

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 4-

6 to remove the bearing cups from the movable yoke.

PR375

INSPECTING

1. Inspect the yoke bores for damage or signs of bear-

ing cup looseness. If bearing cups are loose, the yoke

must be replaced.

CAUTION

Brake fluid is highly corrosive. Do not spill brake fluid

on any surface of the vehicle.

175

PR367B

2. Check that yoke legs are parallel.

PR367A

3. Check splines and flanges for excessive wear, thread

damage, or warpage.

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.

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.

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 bear-

ing 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.

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.

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.

176

Troubleshooting Drive

System

Troubleshooting Brake

System

Problem: Power not transmitted from engine to wheels

Condition Remedy

1. Rear axle shaft serration worn - broken 1. Replace shaft

Problem: Power not transmitted from engine to either front wheel

Condition Remedy

1. Secondary drive - driven gear teeth broken

2. Propeller shaft serration worn - broken

3. Coupling damaged

4. Coupling joint serration worn - damaged

5. Front drive - driven bevel gears broken - damaged

6. Front differential gears/pinions broken - damaged

7. Front drive actuator not operating

1. Replace gear(s)

2. Replace shaft

3. Replace coupling

4. Replace joint

5. Replace gear(s)

6. Replace gears - pinions

7. Replace fuse - drive select switch - front drive actuator

Problem: Braking poor

Condition Remedy

1. Pad worn

2. Brake fluid leaking

3. Master cylinder/brake cylinder seal worn

1. Replace pads

2. Repair - replace hydraulic system

3. Replace seal(s)

Problem: Brake pedal travel excessive

Condition Remedy

1. Brake fluid low

2. Piston seal - cup worn

1. Add fluid to proper level

2. Replace seal - cup

Problem: Brake fluid leaking

Condition Remedy

1. Connection fittings loose

2. Hose cracked

3. Piston seal worn

1. Tighten fittings

2. Replace hose

3. Replace seal

Problem: Brake pedal spongy

Condition Remedy

1. Air trapped in hydraulic system

2. Brake fluid low

1. Bleed hydraulic system

2. Add brake fluid and bleed hydraulic brake system

177

Suspension

The following suspension system components should be

inspected periodically to ensure proper operation.

A. Shock absorber rods bent, pitted, or damaged.

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, deterio-

rated, cracked, or missing.

F. Shock absorber spring broken or sagging.

G. Sway bar mountings tight and bushings secure.

SPECIAL TOOL

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.

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.

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.

AF605D

3. Using a suitable spring compression stand, compress

the shock absorber spring, remove the retainer, and

remove the spring.

CF341

CLEANING AND INSPECTING

1. Clean all shock absorber components in parts-clean-

ing 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 ft-

lb.

4. Remove the vehicle from the support stand.

Rear Shock Absorbers

The rear shock absorbers are Fox Air shocks with spring-

over 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.

Description p/n

Spring Removal Tool 0644-057

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

! WARNING

Shock absorber springs are under high compression

loads. Do not attempt to remove springs without an ade-

quate spring compressor. Sever injury could result.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

178

2. Remove the upper and lower mounting cap screws

and lock nuts. Discard the lock nuts.

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

1. Remove the valve cap; then bleed the air from the air

chamber.

FS141

2. While holding the end cap; unscrew the air cham-

ber.

FS142

3. Drain the oil from the air chamber.

FS143

4. Remove the air chamber from the bottom of the

shock body.

FS144

5. Using a pick, remove the air valve ball from the

nitrogen bladder.

FS145A

6. Using an Allen-wrench, loosen the nitrogen bladder

½ turn.

FS146

7. Using Inflation Needle (p/n 0744-020), remove all

the nitrogen from the shock.

! WARNING

Always wear latex or rubber gloves when servicing a

shock absorber with shock oil.

179

FS147

8. Using a 5/64-in. Allen-wrench, remove the set screw

from the bearing cap.

FS148

9. Using a magnet held against the Allen-wrench,

remove the bleed ball.

FS149

10. Using Spanner Wrench (p/n 0644-453), loosen the

bearing cap.

FS150

11. Remove the shock rod/piston assembly from the

shock body.

FS151

12. Drain the oil from the shock body into a suitable con-

tainer.

13. Using an appropriate floating piston removal tool,

remove the floating piston.

FS152

NOTE: For ease in removing the piston, use the

inflation needle to help vent the shock body.

FS153

14. Clean and inspect all components.

ASSEMBLING/CHARGING

1. Lubricate the O-ring and wiper on the floating piston

with shock oil.

180

FS154

2. Carefully install the floating piston into the shock

body until it is below the threads.

FS155

3. Using an appropriate location tool, install the float-

ing piston to a depth of 7.0 in. while using the infla-

tion needle to vent the shock body.

FS156

4. Using Fox Racing Shock Oil, fill the shock body to

the bottom of the threads; then, allow to sit 1-2 min-

utes to ensure no air is in the oil.

FS157

5. Lubricate the O-ring on the underside of the end cap

with shock oil.

FS158

6. Lower the shock rod into the shock body until the

piston is submerged in oil.

FS159

7. While keeping the shock rod fully extended, thread

the bearing cap into position.

FS160

181

8. Using Spanner Wrench, tighten the bearing cap.

FS161

NOTE: When tightening the bearing cap, note air

and excess oil being bled from the hole in the cap.

FS150A

9. Install the bleed ball and set screw into the bearing

cap.

FS162

FS163

10. Charge the shock with nitrogen to 200 psi.

FS164

11. Using a 3/16-in. Allen-wrench, tighten the

nitrogen bladder.

FS165

12. Install the air valve ball by gently tapping it with a

plastic mallet.

FS166

13. Test the shock for proper operation.

14. Using compressed air, blow all oil from the holes in

the bearing cap.

182

FS167

15. Lubricate the seal on the air chamber with Fox Float

Fluid.

FS168

16. Slide the air chamber onto the shock body.

FS169

17. Add 1 cc of Fox Float Fluid into the chamber.

FS170

18. Thread the air chamber into the end cap until hand-

tight.

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.

FS172

20. Using a hand pump, inflate the air chamber to the

appropriate pressure.

FS173

Payload Pressure

0-250 lb 15 psi

250-500 lb 60 psi (min)

500-750 lb 90 psi (min)

750-1000 lb 150 psi

! WARNING

Do not exceed 150 psi in the shock.

183

21. Install the valve cap.

FS174

22. Install the spring using an appropriate spring com-

pressor 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.

Front A-Arms

REMOVING

1. Secure the vehicle on a support stand to elevate the

front wheels; then remove the wheels.

2. Remove the cotter pin from the nut. Discard the cotter

pin.

PR257

3. Remove the nut securing the hub.

4. Remove the brake caliper. Account for two cap

screws.

CD007

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.

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.

AF626D

10. Remove the cap screws securing the A-arms to the

frame.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

CAUTION

Support the knuckle when removing the cap screws or

damage to the threads will occur.

184

AF610D

11. Remove the snap ring from the ball joint; then remove

the ball joint from the A-arm.

AF616D

CLEANING AND INSPECTING

1. Clean all A-arm components in parts-cleaning solvent.

2. Clean the ball joint mounting hole of all residual Loc-

tite, grease, oil, or dirt for installing purposes.

3. Inspect the A-arm for bends, cracks, and worn bush-

ings.

4. Inspect the ball joint mounting holes for cracks or

damage.

5. Inspect the frame mounts for signs of damage, wear,

or weldment damage.

INSTALLING

1. Apply Loctite Primer “T” to the A-arm socket; then

apply green Loctite #609 to the entire outside diame-

ter of the ball joint. Install the ball joint into the A-arm

and secure with the snap ring.

AF616D

2. Install the A-arm assemblies into the frame mounts

and secure with the cap screws. Only finger-tighten at

this time.

AF610D

3. Route the brake hose through the upper A-arm shock

absorber mount.

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.

185

AF628D

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.

NOTE: During assembly, new cotter pins should

be installed.

AF618D

8. Apply grease to the hub and drive axle splines; then

install the hub assembly onto the drive axle.

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.

PR377B

11. Secure the hub nut (from step 9) to the shaft/axle.

Tighten to 200 ft-lb.

12. Install a new cotter pin and spread the pin to secure the

nut.

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.

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.

2. Place the transmission in park.

3. Remove the wheel.

4. Remove the cotter pin securing the hex nut; then

remove the hex nut.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

186

5. Remove the cap screws and lock nut securing the

shock absorber to the frame and lower A-arm; then

remove the shock absorber.

6. Remove the cap screws securing the boot guard to the

lower A-arm.

AF934

7. Slide the axle out of the knuckle and set aside.

8. Remove the cap screws and lock nuts securing the

knuckle to the A-arms. Discard the lock nuts.

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 A-

arms to the frame; then remove the A-arms.

CLEANING AND INSPECTING

1. Clean all A-arm components in parts-cleaning solvent.

2. Inspect the A-arm for bends, cracks, and worn bush-

ings.

3. Inspect the frame mounts for signs of damage, wear,

or weldment damage.

INSTALLING

1. Install the A-arm assemblies into the frame mounts

and secure with the cap screws and new lock nuts.

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.

4. Apply grease on the drive axle splines; then install the

hub assembly onto the drive axle.

PR221

5. Secure the hub assembly with the nut. Tighten to 200

ft-lb.

6. 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.

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.

9. Secure the boot guard to the lower A-arm with the two

cap screws. Tighten securely.

10. Install the wheel and tighten in 20 ft-lb increments to

40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).

11. Remove the vehicle from the support stand.

187

Wheels and Tires

TIRE SIZE

This vehicle is equipped with low-pressure tubeless tires

of the size and type listed in the General Information sec-

tion. Do not under any circumstances substitute tires of a

different type or size.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 1.41 kg/

cm² (20 psi).

REMOVING

1. Secure the vehicle on a support stand to elevate the

wheels.

2. Remove the nuts securing the wheels; then remove the

wheels.

CLEANING AND INSPECTING

1. Clean the wheels and hubs with parts-cleaning sol-

vent.

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 exist-

ing 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.

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.

! WARNING

Use only Arctic Cat approved tires when replacing tires.

Failure to do so could result in unstable vehicle opera-

tion.

! 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 war-

ranty.

! WARNING

Make sure the vehicle is solidly supported on the sup-

port stand to avoid injury.

! WARNING

Do not operate the vehicle if tire damage exists.

188

Troubleshooting

Problem: Suspension too soft

Condition Remedy

1. Spring preload incorrect

2. Spring(s) weak

3. Shock absorber damaged

4. Rear shock absorbers too soft

1. Adjust preload

2. Replace spring(s)

3. Replace shock absorber

4. Check and adjust air pressure in shocks

Problem: Suspension too stiff

Condition Remedy

1. Spring preload incorrect

2. A-arm-related bushings worn

1. Adjust preload

2. Replace bushing

Problem: Suspension noisy

Condition Remedy

1. Cap screws (suspension system) loose

2. A-arm-related bushings worn

1. Tighten cap screws

2. Replace bushings

Problem: Vehicle pulling or steering erratic

Condition Remedy

1. Vehicle steering is erratic on dry, level surface

2. Vehicle pulls left or right on dry, level surface

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

2014 Prowler HDX Service

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