Arctic Cat 1000 Cruiser Page 202 Service Manual Download

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200

If a system malfunction occurs, a diagnostic trouble code

(DTC) will be generated by the ECM and displayed on the

digital gauge along with a service required (wrench) icon.

The following is a list of conditions that can generate a

malfunction code.



NOTE: The EPS assembly is not serviceable and must

not be disassembled or EPS warranty will be voided.

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

Summary of Contents for 1000 Cruiser

Page 1: ...500 550 700 1000 MUD PRO TRV ATV SERVICE MANUAL 2014...

Page 2: ...s to be completed The technician should use sound judgement when determining which proce dures can be completed based on their skill level and access to appropriate special tools All Arctic Cat ATV pu...

Page 3: ...ne 1000 135 Installing Engine Transmission 1000 180 Fuel Lubrication Cooling 183 Electronic Fuel Injection 183 Throttle Cable Free Play 185 Engine RPM Idle 186 Gas Tank 186 Oil Filter Oil Pump 186 Tes...

Page 4: ...ICAL SYSTEM Ignition Timing 10 BTDC 1500 RPM Spark Plug Cap 5000 ohms Ignition Coil Resistance primary secondary Less than 5 0 ohms 500 550 700 4 8 ohms 1000 12k 19k ohms Ignition Coil Primary Voltage...

Page 5: ...rame Bracket 35 47 ENGINE TRANSMISSION 500 Oil Pump Drive Gear Crankshaft 63 85 Cam Chain Tensioner Guide Cylinder Head 11 15 Cam Chain Tensioner Cylinder 10 14 Water Pump Drive Gear Crankshaft 28 38...

Page 6: ...on Preparation For Storage Arctic Cat recommends the following procedure to pre pare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the ATV t...

Page 7: ...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 lev...

Page 8: ...er 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 Ever...

Page 9: ...TE Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat 5 Squeeze the element by pressing it between the palms of both hands to remove excess solvent Do not twist or wring the...

Page 10: ...over assembly compartment box air filter filter housing and left side right side splash panels must be removed for this procedure A Place Valve Clearance Adjuster onto the jam nut securing the tappet...

Page 11: ...e cannot be run cold values are included 5 While holding the throttle lever in the full open posi tion crank the engine over with the electric starter until the gauge shows a peak reading five to 10 c...

Page 12: ...assembly to the muffler then loosen and remove the arrester CF105A 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...

Page 13: ...tor can reduce cooling capability Using a garden hose wash the radiator to remove any debris preventing air flow The cooling system capacity can be found in General Information The cooling system shou...

Page 14: ...76 2 On the 700 1000 models lift the front of the access panel then slide the panel forward to disengage the two rear tabs 3 On the 700 1000 models move the panel rearward until free of the rack On th...

Page 15: ...te 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 bladder 6...

Page 16: ...DJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizon tally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the ATV...

Page 17: ...ition switch and LCD connector Hydraulic Brake Systems CHECKING BLEEDING The hydraulic brake systems have been filled and bled at the factory To check and or bleed a hydraulic brake sys tem use the fo...

Page 18: ...e on the brake pedal open the bleeder screw and watch for air bubbles Close the bleeder screw before releasing the brake pedal Repeat this proce dure until no air bubbles are present AF637D PR377C NOT...

Page 19: ...owing procedure 1 Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate...

Page 20: ...appropriate spanner wrench tighten the nut to 147 ft lb 500 model or 165 ft lb 550 700 1000 models GZ485A NOTE At this point the CVT cover cap screw can be removed 3 With the vehicle in neutral rotat...

Page 21: ...19 CD083 5 Install the right side footrest see Steer ing Frame Controls 6 Secure the front fender to the footrest with the two cap screws Tighten securely...

Page 22: ...me welds and racks should be checked periodi cally for damage bends cracks deterioration broken components and missing components Front Body Panel Side Panels REMOVING 1 Remove the reinstallable rivet...

Page 23: ...s from the body then remove the screws securing the rear of the front panel to the frame CF237A FI470A 7 Remove the left and right footwells then remove the shift knob Remove the shift lever pivot axl...

Page 24: ...ate 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...

Page 25: ...the footwells CD691A 3 Remove two machine screws securing the battery cover and remove the cover CD687A 4 Disconnect the battery negative cable first then remove the battery 5 Disconnect the taillight...

Page 26: ...NOTE If the front body panel has not been installed see Front Body Panel Side Panels in this section 6 Place the seat into position making sure it locks securely LCD Gauge REPLACING 1 Remove the two...

Page 27: ...f the way Account 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...

Page 28: ...4 Inspect all welded areas for cracks or deterioration 5 Inspect the steering post and steering post brackets for cracks bends or wear 6 Inspect the bearing halves bearing caps and bearing housings fo...

Page 29: ...into position on the steering post then position the LCD gauge on top of the caps and secure with the four cap screws Tighten securely 6 Install the storage compartment box then attach the storage com...

Page 30: ...TE If the slots do not align with the holes in the tie rod ends tighten the nuts just enough to allow installation of the cotter pins AF778D EPS005A 4 Connect the 2 pin and 8 pin connectors to the EPS...

Page 31: ...y seated with the smooth part of the grip facing up 3 Wipe off any excess glue then secure the grip with the handlebar end cap Throttle Control REMOVING 1 Remove the two machine screws securing the th...

Page 32: ...ove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then...

Page 33: ...mbly onto the splines of the shaft 6 Secure the hub assembly with the nut Tighten only until snug PR257 7 Secure the brake caliper to the knuckle with new patch lock cap screws Tighten to 20 ft lb PR2...

Page 34: ...ed acces sories 4 Measure the distance from the outside edge of each handlebar grip to equal reference points on each DE047A 5 Adjust the handlebar direction until the two measure ments are equal then...

Page 35: ...gle 733 559A Shift Lever REMOVING 1 Remove the E clip securing the shift rod to the shift lever 2 Remove two cap screws two self tapping screws and three nylon ties securing the left side splash panel...

Page 36: ...ng the foot pegs to the footrests then remove the foot pegs and footwells 3 Remove the cap screws and flange nuts securing the footrests to the frame then remove the footrests CLEANING AND INSPECTING...

Page 37: ...ALLING 1 Place the assembly into position on the frame and secure with torx head cap screws and any washers 2 Tighten the cap screws securely 3 Route the wiring harness over the rear frame then connec...

Page 38: ...ge box securing the box to the footrest 4 Remove the screw securing the box to the side panel 5 Remove cap screws A and B securing the box to the frame CD045A CLEANING AND INSPECTING 1 Clean all side...

Page 39: ...r 2 Inspect the cargo box for cracks tears and loose mounting 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 INS...

Page 40: ...ighten replace cap screws 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 inflate...

Page 41: ...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...

Page 42: ...ft web to web 60 8 60 9 mm Crankshaft Runout max 0 03 mm VALVES AND GUIDES Valve Face Diameter max intake exhaust 31 6 mm 27 9 mm Valve Tappet Clearance intake cold engine max exhaust 0 1016 mm 0 1524...

Page 43: ...lve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Replace ECM 4 Replace fuel injector 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance...

Page 44: ...ion Remedy 1 Engine oil overfilled 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 Repla...

Page 45: ...mp securing the air filter housing to the front air inlet duct then disconnect the coil con nector and remove the spark plug cap from the spark plug FI519A 8 Disconnect the crankcase breather hose fro...

Page 46: ...ws securing the exhaust pipe to the engine then remove the springs securing the muffler to the exhaust pipe 13 Remove the muffler and exhaust pipe Account for a grafoil seal on each end of the exhaust...

Page 47: ...er 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 o...

Page 48: ...n 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 A...

Page 49: ...he 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...

Page 50: ...s 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...

Page 51: ...s Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC134D CC136D NOTE The valve seals must be replaced 3 Remove the valve...

Page 52: ...g 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...

Page 53: ...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 Cleaning Inspecting Piston Ring Grooves 1 Take an old piston...

Page 54: ...ander 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...

Page 55: ...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...

Page 56: ...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...

Page 57: ...cted 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...

Page 58: ...e 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 sc...

Page 59: ...n 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...

Page 60: ...der 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 bla...

Page 61: ...cian 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 Mag...

Page 62: ...rter 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 prote...

Page 63: ...at 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 rota...

Page 64: ...6 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 c...

Page 65: ...ensor 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 posi tion then install the crankshaft position se...

Page 66: ...ft 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 flywhee...

Page 67: ...emove 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 no...

Page 68: ...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 rol...

Page 69: ...alling 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...

Page 70: ...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 sect...

Page 71: ...ng is damaged in any way the housing must be replaced INSPECTING PRIMARY ONE WAY DRIVE 1 Place the one way clutch onto the clutch shoe assem bly with the green dot or the word OUTSIDE directed away fr...

Page 72: ...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...

Page 73: ...s the clutch shoe 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...

Page 74: ...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 m...

Page 75: ...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 com...

Page 76: ...y 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...

Page 77: ...taining 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...

Page 78: ...rement 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 second...

Page 79: ...suring 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 cranks...

Page 80: ...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 do...

Page 81: ...asher 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 lo...

Page 82: ...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...

Page 83: ...te 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 tim...

Page 84: ...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...

Page 85: ...ghtening 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 occur...

Page 86: ...starter motor and tighten securely FI534A 8 Connect the engine ground wire to the starter mount ing flange and secure with a cap screw tightened to 8 ft lb 9 From the top side install the ECT sensor c...

Page 87: ...beneath the engine transmission then drain the coolant 733 441A CD799A 7 Remove the air filter see Periodic Maintenance 8 Remove the gasline hose connector from the fuel rail FI092E 9 Loosen the clam...

Page 88: ...the throttle body assembly up and away from the engine 14 Remove the E clip securing the shift rod to the engine shift arm then allow the shift rod to swing forward and hang straight down from the shi...

Page 89: ...he sen sor housing CD794 21 On the right side disconnect the stator coil and crankshaft position sensor connectors 22 Disconnect the temperature sensor lead from the wir ing harness CD788 23 Remove th...

Page 90: ...ne 550 700 Top Side Components 88 Removing Top Side Components 89 Servicing Top Side Components 92 Installing Top Side Components 99 Left Side Components 104 Removing Left Side Components 104 Servicin...

Page 91: ...ap 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 orientati...

Page 92: ...haft 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 was...

Page 93: ...he hose 14 Remove the two nuts securing the cylinder to the crankcase CC023D 15 Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase Account for the ga...

Page 94: ...t 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 l...

Page 95: ...ring 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...

Page 96: ...r 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 caliper...

Page 97: ...e top ring slide one end of the ring out of the ring groove 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 no...

Page 98: ...ton pin bore Subtract this measure ment from the measurement in step 1 The difference clearance must not exceed specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of...

Page 99: ...actor 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...

Page 100: ...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 exce...

Page 101: ...ine 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...

Page 102: ...lin der to the crankcase NOTE The two cylinder to crankcase nuts will be tightened in step 11 CC023D 5 Install the coolant hose onto the crankcase union and tighten the clamp C Cylinder Head D Valve C...

Page 103: ...rfaces on the cylinder 14 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the cam shaft lobes onto the camshaft At this point do not seat...

Page 104: ...nstalled 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 CD465 20 Rotate the crankshaft until the first cap screw from step...

Page 105: ...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 u...

Page 106: ...on 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 out...

Page 107: ...ller remove the side cover Account for a gasket and two alignment pins 9 Remove the nut securing the magneto rotor to the crankshaft then install the magneto rotor puller adapter NOTE The puller has l...

Page 108: ...purposes Account for two washers PR430A 15 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 S...

Page 109: ...he 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...

Page 110: ...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 w...

Page 111: ...he 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 S...

Page 112: ...ngine 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...

Page 113: ...E 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 judgmen...

Page 114: ...29B 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...

Page 115: ...10 Remove the nut left hand threads securing the clutch shoe assembly C PR410A 11 Remove the cap screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer CC606 CD987 CD9...

Page 116: ...t 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 crac...

Page 117: ...9 3 Install the oil pump onto the engine then tighten the screws coated with red Loctite 271 to 8 ft lb CD988 4 Install the oil pump drive gear spacer onto the crank balancer shaft Grease the pin and...

Page 118: ...lutch onto the clutch shoe assembly PR399A 9 Lightly 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...

Page 119: ...until the V belt drops into the driven pulley 1 2 to 3 4 inch CF270A H1 020A 16 Place the V belt into position on the driven pulley and over the front shaft PR389 NOTE The arrows on the V belt should...

Page 120: ...ts 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 differ ent lengthed cap...

Page 121: ...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 nec...

Page 122: ...ut 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 rep...

Page 123: ...ing 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 driv...

Page 124: ...nd 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...

Page 125: ...nap 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...

Page 126: ...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 G...

Page 127: ...er 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...

Page 128: ...e 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 th...

Page 129: ...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 mak...

Page 130: ...the engine transmission into the frame then slide the engine rearward as far as possible 2 Slightly raise the rear of the engine and engage the front drive coupler into the splines of the front drive...

Page 131: ...the main wir ing harness 11 Secure the wires to the frame with nylon ties 12 Connect the speed sensor connector to the housing 13 Secure the positive cable to the starter motor 14 Secure all wiring t...

Page 132: ...into position in the battery compart ment then install the battery cables and vent hose Secure with the battery cover 23 Add proper amounts of engine transmission oil and coolant 24 Install the seat...

Page 133: ...uel rails GZ124 5 Disconnect the TPS connector A MAP sensor con nector B and ISC valve connector C from the throttle body then route the harness and connectors away from the engine GZ094A NOTE Using a...

Page 134: ...posi tion switch connector from the gear position switch GZ069A GZ493A 9 Loosen the clamps securing the V belt cooling ducts to the V belt housing then disconnect the cooling ducts GZ037 GZ103B 10 Rem...

Page 135: ...linder GZ099A 14 Remove the front and rear spark plug wires from the spark plugs then disconnect the primary wire con nectors from the coils and remove the coils from the left side of the frame GZ071A...

Page 136: ...in plug and tighten securely GZ009A 19 Remove the coolant hoses from the upper engine coolant outlet pipes then remove the lower coolant hose from the water pump GZ028 GZ369A GZ008 20 Remove the flang...

Page 137: ...ents 163 Center Crankcase Components 166 Separating Crankcase Halves 166 Disassembling Crankcase Half 167 Servicing Center Crankcase Components 169 Assembling Crankcase Half 176 Joining Crankcase Halv...

Page 138: ...t 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 5 Remove the valve cover Account for and note t...

Page 139: ...pin into the engine GZ154A 9 While holding the chain slide the sprocket and cam shaft out of the cylinder head CC266D NOTE Loop the chain over the cylinder head and secure it to keep it from falling i...

Page 140: ...e cap screws securing the water hose union to the cylinder then remove the union from the cylinder Account for an O ring GZ140A 14 Remove the two nuts securing the cylinder to the crankcase GZ141A GZ1...

Page 141: ...00 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 metall...

Page 142: ...cks 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 o...

Page 143: ...seats require servicing or replacement Arctic Cat recommends the components be taken to a qualified machine shop for servicing Measuring Rocker Arm Inside Diameter 1 Using a dial calipers measure the...

Page 144: ...he piston for cracks in the piston pin dome and skirt areas 5 Inspect the piston for seizure marks or scuffing 6 Inspect the perimeter of each piston for signs of excessive blowby Excessive blowby ind...

Page 145: ...ends are aligned on the wire then install the oil ring with the ring gap 90 from the spring gap and the marking E TOP directed toward the top of the piston GZ168 GZ169A 2 Install the second compressi...

Page 146: ...linder 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...

Page 147: ...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...

Page 148: ...be replaced Installing Top Side Components A Pistons B Cylinders 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...

Page 149: ...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 GZ1...

Page 150: ...the front cam shaft 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 GZ130 NOTE At thi...

Page 151: ...nstall the cap screw threads coated with red Loctite 271 and tighten to 11 ft lb Bend the tab to secure the cap screw GZ193 18 Rotate the crankshaft until the first cap screw from step 16 can be tight...

Page 152: ...ad If rotating the cam shaft is necessary for alignment rotate the sprocket inside the chain until the alignment pin can be engaged in the sprocket with the camshaft in the nearest possible position t...

Page 153: ...1 ft lb Bend the tab to secure the cap screw GZ193 CD465 26 Rotate the crankshaft until the first cap screw from step 23 can be addressed then tighten to 11 ft lb Bend the tab to secure the cap screw...

Page 154: ...t into position on the cylinder and secure with the two cap screws CD469 31 Using a flat blade screwdriver rotate the adjuster screw inside the tensioner counterclockwise until the tensioner spring be...

Page 155: ...d 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 procedur...

Page 156: ...Install Magneto Rotor Remover Set and loosen the rotor flywheel then remove the crankshaft protector and rotor flywheel from the crankshaft Account for the flywheel key GZ216 GZ217 5 With the flywhee...

Page 157: ...uring the shift cam plate to the shift cam shaft and remove the shift cam plate then remove the shift shaft H2 022A 12 Remove the snap ring securing the speed sensor trig ger to the shaft and remove t...

Page 158: ...heel FI570 2 Thoroughly clean the rotor flywheel then install the new starter one way clutch and secure with the cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb...

Page 159: ...secure with three cap screws using a drop of red Loctite 271 on each Tighten according to the chart 4 Place the stator wire harness hold down into posi tion then install the crankshaft position senso...

Page 160: ...ift cam stopper spring onto the shift cam stopper and secure with a flat washer and nut Tighten to 8 ft lb H2 019 6 Install the shift cam plate onto the shift cam shaft and secure with the cap screw T...

Page 161: ...from the crankshaft surface and rotor fly wheel bore and install the rotor flywheel onto the crankshaft aligning the keyway with the key Secure with the nut coated with red Loctite 271 tightened to 1...

Page 162: ...not have to be removed from the frame for this procedure Removing Right Side Components A CVT Cover B Driven Clutch C Clutch Cover D Centrifugal Clutch 1 Remove the cap screws securing the CVT cover...

Page 163: ...gnment pins GZ246A 7 Remove the cap screws securing the clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pins GZ246B 8 Using a suitable press remove the clu...

Page 164: ...TING CENTRIFUGAL CLUTCH SHOES 1 Inspect the clutch shoes for wear chips cracks dam age or discoloration If any shoe is damaged replace the centrifugal clutch INSPECTING CLUTCH HOUSING 1 Inspect the cl...

Page 165: ...r pump drive cover and secure with the snap ring flat side away from the bearing GZ441 2 Install the gear onto the driveshaft noting correct ori entation from step 1 of disassembling GZ442 3 Install t...

Page 166: ...e screws threads coated with blue Loctite 242 Tighten to 8 ft lb GZ508 7 Press the clutch housing assembly into the clutch cover until it is seated against the bearing GZ512 8 Install a new O ring int...

Page 167: ...e face onto the clutch shaft 13 Spread the faces of the driven clutch by threading in a cap screw then when the faces are separated insert the belt and push down between the faces GZ065A 14 Place the...

Page 168: ...install the water pump drive housing cover and tighten the cap screws to 8 ft lb GZ437A Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Comple...

Page 169: ...ed If disassembled second ary gear sets will have to be reset for backlash and gear contact see Servicing Center Crankcase Com ponents sub section 4 Remove one cap screw from the right side crankcase...

Page 170: ...en remove the drive idler GZ299A 3 Remove the snap ring securing the water pump idler shaft C in the crankcase then remove the shaft and bearings GZ463A 4 Remove the snap ring securing the oil pump dr...

Page 171: ...establish correct gear tooth contact If only the secondary output driveshaft or secondary output driven gear are replaced proceed to Correct ing Backlash in this sub section 1 Install a new bearing A...

Page 172: ...klash in this sub section Checking Backlash 1 Install the drive bevel gear assembly and driven bevel gear output shaft assembly into the crankcase bottom cover 2 Mount the dial indicator so the tip is...

Page 173: ...ssembling and Inspecting 1 Remove the oil pump cover then remove the gerotor set shaft and pin see Disassembling Crankcase Half in this sub section 2 Inspect the crankcase for scoring discoloration or...

Page 174: ...et separate the inner rotor from the outer rotor and with the ref erence dot directed toward the oil pump cover place the rotor on the shaft then install the drive pin and push the shaft into the roto...

Page 175: ...ting 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...

Page 176: ...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...

Page 177: ...ng 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 bu...

Page 178: ...d the shift forks The countershaft is now ready for installation Assembling Crankcase Half 1 Install the oil pump gerotor assembly and oil pump cover into the crankcase and secure with two cap screws...

Page 179: ...Z474 NOTE It will be necessary to rotate the crankshaft back and forth to engage the teeth of the oil pump and countershaft gears 6 Install the driveshaft then with a flat washer on each end of the re...

Page 180: ...the radius directed toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of Loctite 5900 or suitable substitute sealant to the crankcase mating surface NOTE Apply sealan...

Page 181: ...backlash 6 Install the locating ring in the crankcase assembly then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly...

Page 182: ...GZ110A GZ119 4 Align the rear output shaft and the rear gear case flange and install the cap screws coated with red Loctite 271 Tighten to 20 ft lb 5 Align the engine with the mounting brackets and in...

Page 183: ...connect all exhaust junc ture springs GZ099A GZ372 11 Install the intake manifolds and tighten to 8 ft lb then install the throttle body and secure with the hose clamps GZ106 GZ107 GZ090B 12 Connect...

Page 184: ...ts Tighten securely 17 Install the front body panel footrests foot wells and front rack then install the upper bumper sup port to frame cap screws see Steering Frame Con trols 18 Connect the negative...

Page 185: ...switch key 2 Remove the seat then disconnect the battery 3 Remove the storage compartment cover and air filter housing cover then remove the air filter 4 Loosen the clamp securing the air filter hous...

Page 186: ...throttle arm cover and disconnect the throttle cable then remove the throttle body from the ATV GZ383A 6 Use tape to cover and seal the intake opening INSTALLING 500 550 700 1 Install the throttle bo...

Page 187: ...e to the throttle body then remove the tape from the intake manifold and install the throttle body using a new O ring Tighten the cap screws securely GZ381A 2 Connect the three wiring connectors to th...

Page 188: ...up assembly 2 Place the gas tank into position in the frame then install the cap screws Tighten securely 3 Connect the gasline hose from the throttle body then connect the fuel gauge connector 4 Fill...

Page 189: ...to their respective fittings and secure with the clamps Liquid Cooling System When filling the cooling system use premixed Arctic Cat Antifreeze While the cooling system is being filled air pockets ma...

Page 190: ...to the cylinder head Account for an O ring and a thermostat Removing 1000 NOTE The thermostat is located in a housing in line with the upper radiator hoses under the air fil ter housing GZ036A 1 Drai...

Page 191: ...ced 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 the engine transmission 3 Remove the four torx head cap screws s...

Page 192: ...00 NOTE The water pump is a non serviceable compo nent It must be replaced as an assembly Removing 1 Remove the coolant drain plug then remove the radia tor cap and drain the coolant into a suitable c...

Page 193: ...dicated 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 REMOVING 1 Remove the rear rack and fenders see Steer ing...

Page 194: ...n ing then carefully guide the fuel pump into position taking care not to damage the float or float lever KX190 3 Rotate the fuel pump until the match marks align then install the mounting screws and...

Page 195: ...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 330...

Page 196: ...to the battery for a minimum 1 hour after the Maintenance Charge Indicator D illu minates If the battery becomes hot to the touch stop charging Resume after it has cooled 7 Once the battery has reach...

Page 197: ...2 3 When the brake pedal is depressed the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance replace the switch Brakelight Switch Handlebar Control To access the co...

Page 198: ...dings are not as indicated the sensor must be replaced 8 Install the sensor and tighten securely 9 Connect the leads Fan Motor The connector is the black two prong one located above the oil cooler rad...

Page 199: ...and wiring harness are not a service able components and must be replaced as an assembly Ignition Coil NOTE On the 1000 models the following proce dures should be performed on both ignition coils The...

Page 200: ...rom the pressure sensor located on top of the throttle body 2 Select DC Voltage on the tester and turn the ignition switch to the ON position 3 Connect the black tester lead to the black green wire an...

Page 201: ...5 Leave the black tester lead connected then connect the red tester lead to the signal lead S pin 6 Slowly move the ATV forward or backward the meter must show 0 and 6 12 DC volts alternately NOTE If...

Page 202: ...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 norm...

Page 203: ...th 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 a...

Page 204: ...to the LIGHTS position 6 Connect either tester lead to pin A then connect the other tester lead to pin B 7 The meter must show less than 1 ohm 8 Connect either tester lead to pin C then connect the o...

Page 205: ...and front fenders must be removed see Steering Frame Con trols 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to one red yellow wire then connect the black tester wire to...

Page 206: ...8 Select Differential Lock on the drive select switch then connect the red tester lead to the white orange wire in the supply harness The meter must show 0 DC volts 9 Connect the tester lead to the wh...

Page 207: ...switch in the RUN position 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 mo...

Page 208: ...The regulator rectifier is located under the rear rack and rear fenders TESTING 1 Start engine and warm up to normal operating tem perature then connect a multimeter to the battery as follows 2 Selec...

Page 209: ...ignition timing can aid in troubleshooting other components To verify ignition timing use the following procedure 1 Attach the Timing Light to the spark plug high ten sion lead then remove the timing...

Page 210: ...on If the meter readings are not as specified the tilt sensor is defective CD709 NOTE When replacing the sensor after testing make sure the arrow marking is directed up CD705A Throttle Position Sensor...

Page 211: ...nd the three pin plug on the TPS for contamination bro ken 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 specifi...

Page 212: ...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...

Page 213: ...B fan relay C fan fuse D wiring connections 5 High Temperature Rev Limiter 5000 RPM 230 F Fuel Sensor FUEL Diagnostic Mode EFI010 Display Fuel level signal from the fuel level sensor measured in ohms...

Page 214: ...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 t...

Page 215: ...orted 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 interconn...

Page 216: ...n 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 intermitt...

Page 217: ...fier 4 Replace battery Problem Battery overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier resistor damaged defective 3 Regulator rectifier poorly grounded 1 Replace...

Page 218: ...ed REMOVING 1 Disconnect the connector on the actuator harness 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the actuator AG926 3 Remove the mounting cap screw f...

Page 219: ...ct switch several times 7 Secure the wiring harness to the frame with a nylon cable tie Front Differential REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the...

Page 220: ...bber mallet tap the end of the axle and free it from the knuckle assembly AF628D 11 Pull the steering knuckle away from the axle KX151 12 Support the axle to not allow it to drop or hang 13 Remove the...

Page 221: ...uator to the gear case then remove the actuator AG925 18 Remove the lower differential mounting cap screw Account for a lock nut and washers CD026 19 Remove the upper differential mounting cap screws...

Page 222: ...Remove the fork collar and spring Note the location of all the components for assem bling purposes GC015 CD106 3 Using a boot clamp pliers or suitable substitute remove the boot clamps then remove th...

Page 223: ...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...

Page 224: ...ring 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 p...

Page 225: ...he 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 bea...

Page 226: ...ery 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 NOTE All bearings must be installed in t...

Page 227: ...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 g...

Page 228: ...ith 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 b...

Page 229: ...fferential housing cover assembly install the cover with existing cap screws coated with green Loctite 609 Account for the ID tag Tighten the cap screws evenly to 23 ft lb NOTE Grease can be applied t...

Page 230: ...opposite side INSTALLING DIFFERENTIAL 1 Align the splined input yoke with the front output splines then place the differential into position on the frame and install the cap screws coated with blue Lo...

Page 231: ...ith the lock nuts Tighten to 30 ft lb then install 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 Insta...

Page 232: ...holding the axle in pull the CV cup from the gear case NOTE Keeping the axle level will aid in removal PR729C REMOVING FRONT DRIVE AXLE NOTE For removing a front drive axle see Front Differential in t...

Page 233: ...NOTE In the outboard boot use the final 40 grams 1 3 of contents of grease from the pack in the bear ing housing INSTALLING REAR DRIVE AXLE 1 Push the axle shaft into the CV cup to release the detent...

Page 234: ...tall and spread a new cotter pin 4 Slide the hub w brake disc into position in the steer ing knuckle followed by a washer and hex nut Tighten finger tight at this time 5 Install the brake caliper on t...

Page 235: ...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 mea...

Page 236: ...taining 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 a...

Page 237: ...irected outward then install the clutch pack into the basket GZ176 5 Using a new gasket install the assembled input shaft housing onto the rear drive gear case and secure with the three cap screws Tig...

Page 238: ...ake disc to the hub with the four cap screws coated with blue Loctite 243 Tighten to 15 ft lb 2 Apply grease to the splines in the hub 3 Install the hub assembly onto the shaft PR290 4 Secure the hub...

Page 239: ...light switch from the master cyl inder housing by gently pressing it toward the pivot pin hole in the housing then lay it aside leaving the switch and wiring harness connected BC205 5 Remove the clamp...

Page 240: ...opened 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 dist...

Page 241: ...ke caliper housing then remove four O rings from the brake caliper housing noting the location of the different sized O rings Discard all seals O rings and crush wash ers CLEANING AND INSPECTING 1 Cle...

Page 242: ...liper PR719C 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...

Page 243: ...sion during hard braking resulting in greatly increased stopping distance or loss of control leading to injury or death Problem Power not transmitted from engine to wheels Condition Remedy 1 Rear axle...

Page 244: ...ic system correct or repair leaks 5 Replace master cylinder Problem Brake lever travel excessive Condition Remedy 1 Hydraulic system entrapped air 2 Brake fluid low 3 Brake fluid incorrect 4 Piston se...

Page 245: ...ch front shock absorber to the frame and the upper A arm Account for bushings and sleeves from each AF605D 3 Remove the two cap screws and nut securing each rear shock absorber to the frame and lower...

Page 246: ...OTE Do not allow the brake caliper to hang from the cable hose 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 fro...

Page 247: ...F616D 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 th...

Page 248: ...ighten to 40 ft lb steel wheels or 80 ft lb aluminum 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 b...

Page 249: ...Tighten to 35 ft lb 3 Tighten the hardware securing the A arms to the frame from 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...

Page 250: ...e 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 as nece...

Page 251: ...ition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Auxiliary brake adjusted incorrectly 6 Rear suspension arm related bu...

Page 252: ...250 NOTES...

Page 253: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 841...

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Summary of Contents for 1000 Cruiser

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Arctic Cat 1000 Cruiser, Service Manual

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Summary of Contents for 1000 Cruiser

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