Arctic Cat 1000 2012 Service Manual Download Page 144

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2. Connect the headlight connectors to the appropriate

headlights and the front accessory plug wires to the

accessory plug.

CD681

3. Make sure the rubber grommets and bushings are in

place; then place the front rack into position and

secure with the cap screws and lock nuts. Tighten

securely.

4. Install the footwells and foot rests. Tighten securely.
5. Install the cap screws securing the front body panel

to the frame and rear panel.

FI470A

6. Install the shift lever spring, shift lever, and pivot

axle; then tighten the axle nut securely.

CD779

7. Install the instrument pod and ignition switch; then

secure with two reinstallable rivets and the ignition

switch retaining ring.

8. Set the storage compartment box into position; then

install the storage compartment cover making sure

the mounting tabs engage the slots. Slide rearward to

secure and lock by engaging the lid lock.

FI468

FI467

9. Install the steering post cover and secure with the

reinstallable rivets; then install and secure the radia-

tor access panel.

FI466A

FI465A

10. Install the side panels.

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

www.mymowerparts.com

Summary of Contents for 1000 2012

Page 1: ...rocedures Such efficiency not only helps build consumer confidence but also saves time and labor All Arctic Cat ATV publications and decals display the words Warning Caution Note and At This Point to...

Page 2: ...4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System Brake System 7 Suspension 8 Steering Frame Controls 1 2 3 4 5 6 7 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 w...

Page 3: ...ations 1 2 Torque Specifications 1 2 Torque Conversions ft lb N m 1 3 Break In Procedure 1 3 Gasoline Oil Lubricant 1 4 Genuine Parts 1 4 Preparation For Storage 1 5 Preparation After Storage 1 5 FOR...

Page 4: ...ue Less than 1 ohm black to black Peak Voltage trigger 2 0 volts green to blue AC Generator Output no load 60 AC volts 5000 RPM black to black Generator Output approx 325W 5000 RPM EXHAUST COMPONENTS...

Page 5: ...1 Magneto Cover Crankcase 8 11 Oil Pump Drive Gear Crank Balancer Shaft 63 85 Output Shaft Nut Output Shaft 59 80 Outer Magneto Cover Left Side Cover 6 8 Magneto Rotor Nut Crankshaft 107 145 Cam Sproc...

Page 6: ...all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives FILLING GAS TANK Since gasoline expands as its temperature rises the gas tank must be filled to its rated...

Page 7: ...nd correctly preparing it will assure many miles and hours of trouble free riding Arctic Cat recommends the following procedure to pre pare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove...

Page 8: ...4 Spark Plug 2 5 Muffler Spark Arrester 2 5 Engine Transmission Oil Filter 2 6 Liquid Cooling System 2 7 Front Differential Rear Drive Lubricant 2 8 Nuts Bolts Cap Screws 2 9 Headlights Taillight Bra...

Page 9: ...r C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R Carburetor Float Chamber D Engine Idle RPM I I A Engine Transmission Oil Level I A Engine Transmission Oil Filter R R R R R Oil Strainer C F...

Page 10: ...and the air fil ter frame assembly 3 Remove the foam element from the frame making sure not to tear the element CD747 4 Fill a wash pan larger than the element with a non flammable solvent then dip t...

Page 11: ...valve adjuster handle in place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in Feeler Gauge Procedure su...

Page 12: ...trong spark keep the plug free of carbon ATV 0051 Adjust the gap to correct specification see Section 1 for proper type and gap Use a feeler gauge to check the gap ATV0052 When installing the spark pl...

Page 13: ...n plug and tighten to 16 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug 8 Start the engine while the ATV is outside on level ground a...

Page 14: ...fill the cooling system to the bot tom of the stand pipe in the radiator neck Checking Filling 1 Remove the four screws securing the radiator access panel FI476 2 Move the panel forward until free of...

Page 15: ...ropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole NOTE If the differential rear drive lubricant is con taminated with water inspect the drain plug fill plug and or blad...

Page 16: ...rt the bulb socket assembly into the housing and turn it clockwise to secure CHECKING ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizon tally The geometric center of the HI...

Page 17: ...st ment 4 Install the left side engine cover and seat making sure the seat locks securely in place NOTE An E Error in the gear position icon indi cates no signal or a poor ground wire connection in th...

Page 18: ...tem D At this point perform step B and C on the other FRONT bleeder screw then move to the REAR bleeder screw and follow the same procedure E Repeat step D until the brake lever is firm 4 To bleed the...

Page 19: ...nuckle then remove the pads PR237 C Install the new brake pads D Secure the caliper to the knuckle and or axle housing with new patch lock cap screws Tighten to 20 ft lb PR377B E Install the wheel Tig...

Page 20: ...CD078 3 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 insta...

Page 21: ...he top of the driven clutch 4 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 locat...

Page 22: ...3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 Table of Contents 3 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mym...

Page 23: ...Clearance cold engine intake exhaust 0 08 0 12 mm 0 13 0 17 mm Valve Guide Stem Clearance max 0 013 mm Valve Guide Valve Stem Deflection max wobble method 0 35 mm Valve Guide Inside Diameter 5 000 5...

Page 24: ...e out of adjustment 1 Clean plug 2 Replace magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve...

Page 25: ...d contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil replace oil 2 Replace service rings cylinder 3 Repla...

Page 26: ...e battery and the battery vent hose then remove the battery 3 Remove the radiator access cover steering post cover and storage compartment cover assembly then remove the storage compartment box 4 Remo...

Page 27: ...ove the cooling duct boot from the V belt housing outlet CD793 CD515A 12 Remove the left side foot peg and footwell see Sec tion 8 13 Secure the carburetor assembly up and away from the engine 14 Remo...

Page 28: ...advisable to lock the brake when loosen ing the cap screws securing the rear driveshaft 19 Remove the positive cable from the starter motor and route it out of the way CD796 20 Disconnect the speed s...

Page 29: ...k the engine up in this position CD811 27 Remove the first small boot clamp then remove the output flange and driveshaft from the rear drive cou pler CD812A CD813 28 Remove the block from under the en...

Page 30: ...op dead center of the compression stroke 1 Remove the two tappet covers CC001D NOTE Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them sepa...

Page 31: ...the washer tabs down and remove the two cap screws securing the sprocket to the camshaft then drop the sprocket off the camshaft CC013D 6 While holding the chain slide the sprocket and cam shaft out...

Page 32: ...en detach the hose 11 Remove the two nuts securing the cylinder to the crankcase CC023D 12 Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase Account...

Page 33: ...of the groove Servicing Top Side Components NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary VALVE ASSEMBLY When servicing valve assembly inspect valve...

Page 34: ...nt for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC136D NOTE The valve seals must be replaced 3 Remove the valve springs then i...

Page 35: ...e 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 V...

Page 36: ...orn 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 CC400D 2 Remove each ring by working it toward the dome...

Page 37: ...the measurement in step 1 The difference clearance must not exceed specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings...

Page 38: ...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 c...

Page 39: ...ompressed 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 pist...

Page 40: ...er 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 t...

Page 41: ...tightened in step 11 CC023D 5 Install the coolant hose onto the crankcase union and tighten the clamp C Cylinder Head D Valve Cover NOTE Steps 1 5 in the preceding sub section must precede this proce...

Page 42: ...ft 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 para...

Page 43: ...ure 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...

Page 44: ...ll the cap screw into the end of the chain tensioner 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...

Page 45: ...ve the four cap screws securing the outer mag neto cover to the left side cover then remove the outer magneto cover Account for the gasket 2 Remove the flange nut securing the bushing to the crankshaf...

Page 46: ...otor Remover Set and the appropriate crankshaft protector remove the rotor flywheel assem bly from the crankshaft Account for the key then remove the starter clutch gear assembly and washer CD939A CD9...

Page 47: ...e starter clutch gear clockwise It should lock up to the rotor flywheel Rotate the gear counterclockwise and it should turn freely If it moves or locks up both ways the starter clutch must be replaced...

Page 48: ...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 cham...

Page 49: ...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 pri...

Page 50: ...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 CD...

Page 51: ...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...

Page 52: ...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 th...

Page 53: ...er and IN ORDER CC829B 8 Remove the one way clutch D from the clutch housing Note the location of the green alignment dot or the word OUTSIDE for installing purposes 9 Using a hydraulic press remove t...

Page 54: ...unt for a cap screw washer pin and spacer CC606 CD987 CD993 13 Using an impact wrench remove the cap screws secur ing the final drive carrier bearing housing E then remove the housing and account for...

Page 55: ...d 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 directi...

Page 56: ...securely CD988 4 Install the oil pump drive gear spacer onto the crank balancer shaft Grease the pin and insert it into the shaft then install the drive gear making sure the raised side of the gear is...

Page 57: ...ghtly grease the clutch housing seal then insert the left fixed drive spacer CF088A CF085A 10 Apply grease to the outer edges of the clutch hous ing then from inside the clutch cover install the clutc...

Page 58: ...xed face then tighten the cap screw until the V belt drops into the driven pulley 1 2 to 3 4 inch GZ075 16 Place the V belt into position on the driven pulley and over the front shaft PR389 NOTE The a...

Page 59: ...the crankcase halves Note the location of the differ ent lengthed cap screws 2 Remove the left side cap screws securing the crank case halves Note the location of the differ ent lengthed cap screws 3...

Page 60: ...n 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 c...

Page 61: ...dary 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 a...

Page 62: ...lash 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...

Page 63: ...ge 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 bloc...

Page 64: ...A 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 GZ319...

Page 65: ...g 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 revers...

Page 66: ...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...

Page 67: ...kshaft 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 dot...

Page 68: ...ug 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...

Page 69: ...the boot with new clamps CD821 4 Remove the block from beneath the engine then align the rear drive flanges and secure with four cap screws Tighten to 20 ft lb CD824 5 Install the engine mounting thro...

Page 70: ...per engine bracket with cable ties 15 Secure the two coolant hoses to the engine 16 Secure the crankcase vent hose to the air cleaner housing then secure the inlet boot and carburetor to the air filte...

Page 71: ...Install the seat CAUTION Battery acid is harmful if it contacts eyes skin or cloth ing Care must be taken whenever handling a battery CAUTION If the engine had a major overhaul or if any major part w...

Page 72: ...Carburetor 4 2 Electric Choke 4 6 Throttle Cable Free Play 4 7 Engine RPM Idle 4 7 Gas Tank 4 8 Oil Filter Oil Pump 4 8 Testing Oil Pump Pressure 4 8 Liquid Cooling System 4 9 Vacuum Pulse Fuel Pump 4...

Page 73: ...or from the intake pipe 5 Remove the screw securing the throttle actuator cover to the carburetor then remove the cover PR154B 6 Remove the throttle cable from the actuator arm PR162C 7 Loosen the out...

Page 74: ...Account for a spring spring seat and the jet needle CC746 3 Remove the three screws securing the pump housing Account for the diaphragm assembly spring and U ring in the housing CC748 4 Remove the Phi...

Page 75: ...iston diaphragm for cracks imperfections in the casting or cracks and tears in the rubber 7 Inspect float for damage 8 Inspect gasket and O rings for distortion tears or noticeable damage 9 Inspect ti...

Page 76: ...into position making sure the O ring is properly positioned then secure with the Phillips head screws CC750 CC749 7 Place the U ring into the pump housing Position the spring and diaphragm assembly li...

Page 77: ...Connect the hose from the carburetor to the gas tank 8 As necessary secure the air intake snorkel the air filter housing cover or the air filter housing 9 Install the seat Electric Choke REMOVING 1 Di...

Page 78: ...e Cable Free Play To adjust the throttle cable free play follow this proce dure 1 Slide the rubber boot away then loosen the jam nut from the throttle cable adjuster AL611D 2 Turn the adjuster until t...

Page 79: ...enever internal engine components wear excessively or break and whenever oil is contami nated the oil pump should be replaced The oil pump is not a serviceable component Testing Oil Pump Pressure NOTE...

Page 80: ...the radiator then secure with existing hardware 2 Place the radiator with grommets and collars into position on the frame then install the cap screws and nuts Tighten securely 3 Install the upper and...

Page 81: ...E The water pump is a non serviceable compo nent It must be replaced as an assembly Removing 1 Remove the radiator cap then remove the water pump drain and drain the coolant CC789 2 Drain the oil from...

Page 82: ...n connect a hose and suitable pressure gauge to the fuel pump output fitting CD815 2 Start the engine Fuel pump pressure should read 0 18 0 25 kg cm2 2 5 3 5 psi CD816 REMOVING 1 Remove the seat then...

Page 83: ...impaired Condition Remedy 1 High RPM cut out against RPM limiter 2 Main jet obstructed 3 Needle jet obstructed 4 Vacuum piston not operating properly 5 Filter obstructed 6 Float height incorrect 1 Sh...

Page 84: ...Cooling Fan Switches 5 5 Fan Motor 5 5 Power Distribution Module PDM 5 5 Ignition Coil 5 6 Speed Sensor 5 7 Ignition Switch 5 7 Handlebar Control Switches 5 8 Drive Select Switch 5 9 Front Drive Diff...

Page 85: ...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 flui...

Page 86: ...not perform to operator expectations bring the battery to an autho rized Arctic Cat dealer for further troubleshooting RPM Limiter NOTE The ATV is equipped with a CDI unit that retards ignition timin...

Page 87: ...the access panel NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Connector 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the orange w...

Page 88: ...the switch leads Fan Motor The connector is the black two prong one located above the radiator NOTE The ignition switch must be in the ON posi tion RESISTANCE Fan Motor Connector 1 Set the meter sele...

Page 89: ...relays are interchangeable NOTE The module and wiring harness are not a service able components and must be replaced as an assembly Ignition Coil The ignition coil is on the frame above the engine To...

Page 90: ...ack tester lead to the ground lead G CD885A 3 Turn the ignition switch to the ON position 4 The meter must show 6 12 DC volts 5 Leave the black tester lead connected then con nect the red tester lead...

Page 91: ...onnector is the yellow one next to the steering post To access the connector the steering post cover and the right side fender splash shield must be removed see Section 8 NOTE These tests should be ma...

Page 92: ...side of the connector RESISTANCE 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the red wire then connect the black tester lead to the white wire 3 With the select swit...

Page 93: ...ngine running at the specified RPM all wire tests must show 60 AC volts NOTE If both stator coil tests failed replace the stator coil assembly RESISTANCE Charging Coil 1 Disconnect the stator coil plu...

Page 94: ...must be in the ON posi tion the engine stop switch in the RUN position and the shift lever in the NEUTRAL position 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to...

Page 95: ...e of all four connectors Also the ignition switch must be in the LIGHTS position NOTE The LO beam is the outside bulb and the HI beam is the inside bulb 1 Set the meter selector to the DC Voltage posi...

Page 96: ...just carburetor 7 Adjust carburetor Problem Spark plug electrodes overheat or burn Condition Remedy 1 Spark plug incorrect too hot 2 Engine overheats 3 Spark plug loose 4 Mixture too lean 1 Replace pl...

Page 97: ...d acid 4 Battery electrolyte insufficient lead acid 1 Replace battery 2 Replace battery 3 Charge battery add distilled water 4 Keep electrolyte to prescribed level Problem Battery discharges too rapid...

Page 98: ...ential Lock 6 2 Front Differential 6 3 Drive Axles 6 16 Rear Gear Case 6 19 Hub 6 20 Hand Brake Lever Master Cylinder Assembly 6 21 Hydraulic Brake Caliper 6 23 Troubleshooting Drive System 6 26 Troub...

Page 99: ...is in the ON position The front drive actuator is located on the side of the front drive input housing With the engine stopped and the ignition switch in the ON position a momentary whir ring sound ca...

Page 100: ...s 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...

Page 101: ...95D 9 Remove the tie rod lock nuts AF896D 10 Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft then using a rubber mallet tap the end of the axle and...

Page 102: ...inner fender panels 17 Using a T 30 torx wrench remove the three screws securing the front drive actuator to the gear case then remove the actuator AG925 18 Remove the lower differential mounting cap...

Page 103: ...nician should use dis cretion and sound judgment 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 Rem...

Page 104: ...aring 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 th...

Page 105: ...lamp and the rear boot with an appropriate boot clamp CD112 CD099 5 Place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to 23 ft lb NOT...

Page 106: ...ng of the differential lock assembly and set aside Note position of parts for assembling purposes KX175 5 Remove the left differential bearing flange assembly and account for a shim Mark the shim as l...

Page 107: ...er 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 CC879 4 Remove a...

Page 108: ...g 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 tan...

Page 109: ...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...

Page 110: ...ndicator 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 dec...

Page 111: ...e cover with existing cap screws coated with green Loctite 609 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...

Page 112: ...gn the splined input yoke with the front output splines then place the differential into position on the frame and install the cap screws coated with blue Loctite 243 washers and flex lock nuts Tighte...

Page 113: ...nstall and spread the cotter pins AF896D AF895D 9 Install the brake calipers and secure with new patch lock cap screws tightened to 20 ft lb AF894D 10 Install the wheels and tighten to 40 ft lb steel...

Page 114: ...h the axle shaft firmly toward the gear case to release the internal lock then while holding the axle in pull the CV cup from the gear case PR729B PR725A REMOVING FRONT DRIVE AXLE NOTE For removing a...

Page 115: ...o the hex nut CD027 7 Install the wheel Tighten to 40 ft lb steel wheels or 80 ft lb aluminum wheels 8 Remove the ATV from the support stand and release the brake lever lock INSTALLING FRONT DRIVE AXL...

Page 116: ...ng 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 roughn...

Page 117: ...vate the wheel then remove the wheel 2 Remove the cotter pin from the nut NOTE During assembly new cotter pins should be installed KX041 3 Remove the hex nut securing the hub 4 Remove the brake calipe...

Page 118: ...le 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 com pletely NOTE Compres...

Page 119: ...switch for corrosion cracks missing or broken mounting tabs or broken and frayed wiring NOTE If the brakelight switch is determined to be not serviceable see Section 5 INSTALLING 1 Position the brake...

Page 120: ...e 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 fu...

Page 121: ...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...

Page 122: ...caliper Tighten to 20 ft lb 8 Fill the reservoir then bleed the brake system see Section 2 9 Install the wheel Tighten to 40 ft lb steel wheels or 80 ft lb aluminum wheels 10 Remove the ATV from the s...

Page 123: ...Replace gears pinions 7 Replace gear s 8 Replace axle 9 Replace axle Problem Braking poor Condition Remedy 1 Pad worn 2 Pedal free play excessive 3 Brake fluid leaking 4 Hydraulic system spongy 5 Mast...

Page 124: ...NSION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 3 Rear A Arms 7 5 Wheels and Tires 7 6 Troubleshooting 7 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983...

Page 125: ...NG AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Clean all shock absorber components using a pres sure washer 2 Inspect each shock r...

Page 126: ...the knuckle then remove the tie rod end from the knuckle AF618D 7 Remove the cap screws securing the ball joints to the knuckle PR203 8 Tap the ball joints out of the knuckle then remove the knuckle 9...

Page 127: ...nto 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 then secure the hose to the A arm with a...

Page 128: ...minum wheels 14 Remove the ATV from the support stand Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove...

Page 129: ...m step 1 to 50 ft lb 4 Apply grease on the drive axle splines then install the hub assembly onto the drive axle PR290 5 Secure the hub assembly with the nut Tighten only until snug 6 Secure the brake...

Page 130: ...ing the rotation arrow if applicable must indicate forward direction of rotation AF612D CHECKING INFLATING 1 Using an air pressure gauge measure the air pressure in each tire Adjust the air pressure a...

Page 131: ...ar wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Auxiliary brake adjusted incorrectly 6 Rear suspension arm related bushing worn 7 Rear...

Page 132: ...trol 6 Steering Knuckles 6 Measuring Adjusting Toe Out 8 Shift Lever 10 Front Rack 10 Front Bumper Assembly 10 Front Body Panel Side Panels 10 Footrests 14 Belly Panel 14 Exhaust System 14 Rear Body P...

Page 133: ...wing procedure 1 Remove the two reinstallable rivets securing the instrument pod then remove the ignition switch retaining ring 2 Remove the two nuts securing the mounting studs then remove the gauge...

Page 134: ...ount for four handlebar caps CD762 7 Remove two cap screws securing the upper steering post bearing to the frame Account for two housings CD760 8 Using a suitable lift stand raise the ATV enough to re...

Page 135: ...hous ings then position on the steering post and secure the housings to the frame with two cap screws Tighten to 20 ft lb CD760 3 Install the tie rods and secure with the slotted nuts Tighten to 30 f...

Page 136: ...or damaged in any way replacement is nec essary 1 Inspect the grip for wear cuts or cracks 2 Inspect the grip for deterioration 3 If a grip is damaged cut the grip lengthwise using a sharp knife or b...

Page 137: ...arm into position Secure with the cap screw lock washer and washer AF679D 2 Using a pair of needle nose pliers place the spring into position on the actuator arm AF680D 3 Place the two halves of the...

Page 138: ...e for cracks breaks or porosity 4 Inspect threads for stripping or damage ASSEMBLING AND INSTALLING 1 Install the bearing then install the snap ring making sure it seats into the knuckle PR287A 2 Inst...

Page 139: ...rly inflated to the recommended pressure NOTE Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur 3 Place the ATV in a level position taking care not to push dow...

Page 140: ...arallel to the belly panel AF789D 9 Measure the distance between the marks at a height parallel to the belly panel at the front side then record the measurement 10 Push the ATV forward until the marks...

Page 141: ...ng 3 Inspect threaded areas of all mounting bosses for stripping 4 Inspect for missing decals and or reflectors INSTALLING 1 Place the rack into position on the frame and front fender panel Install th...

Page 142: ...nstallable rivets securing the instrument pod then remove the instrument pod FI463A FI464A 5 Remove the cap screws and lock nuts securing the front rack to the frame then remove the front rack Account...

Page 143: ...the rear up to clear the handlebar CD765A NOTE It may be necessary to rotate the body panel to the right to align the opening with the handlebar CLEANING AND INSPECTING NOTE Whenever a part is worn ex...

Page 144: ...pring shift lever and pivot axle then tighten the axle nut securely CD779 7 Install the instrument pod and ignition switch then secure with two reinstallable rivets and the ignition switch retaining r...

Page 145: ...the underside of the frame then remove the belly panel 2 Place the belly panel into position on the underside of the frame then install the machine screws and shoulder washers Tighten securely Exhaust...

Page 146: ...the rear rack in position with the bushings and secure with the cap screws and lock nuts Tighten securely 3 Install one shoulder screw and three plastic rivets on each side to secure the front of the...

Page 147: ...Steering oscillation Condition Remedy 1 Tires inflated unequally 2 Wheel s wobbly 3 Wheel hub cap screw s loose missing 4 Wheel hub bearing worn damaged 5 Tie rod ends worn loose 6 Tires defective in...

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