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4-1

4

SECTION 4 -

FUEL/LUBRICATION/COOLING

TABLE OF

CONTENTS

Fuel/Lubrication/Cooling ......................................... 4-2
Carburetor Specifications (400/650)........................ 4-2
Carburetor Schematics (400/650) ........................... 4-2
Carburetor (400/650)............................................... 4-2
Electric Choke (400/650)......................................... 4-7
Electronic Fuel Injection (EFI) ................................. 4-8
Throttle Cable Free-Play ....................................... 4-10
Engine RPM (Idle) ................................................. 4-11
Gas Tank ............................................................... 4-11
Oil Filter/Oil Pump ................................................. 4-12
Testing Oil Pump Pressure.................................... 4-12
Oil Cooler (400/700/H2) ........................................ 4-12
Liquid Cooling System (H1/H2) ............................. 4-13
Electric Fuel Pump/Fuel Level Sensor (EFI) ......... 4-16
Vacuum Pulse Fuel Pump (400/650)..................... 4-18
Troubleshooting (400/650)..................................... 4-19
Troubleshooting (EFI) ............................................ 4-20

Manual

Table of Contents

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Summary of Contents for 1000 H2

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

Page 2: ...Thundercat 1000 TRV Cruiser Mud Pro TABLE OF CONTENTS Click on blue text to go Foreword 1 General Information Specifications 2 Periodic Maintenance 3 Engine Transmission 4 Fuel Lubrication Cooling 5...

Page 3: ...neral Specifications 1 2 Torque Specifications 1 3 Torque Conversions ft lb N m 1 5 Tightening Torque General Bolts 1 5 Break In Procedure 1 5 Gasoline Oil Lubricant 1 5 Genuine Parts 1 6 Preparation...

Page 4: ...qt Differential Capacity 275 ml 9 3 fl oz Rear Drive Capacity 250 ml 8 5 fl oz Engine Oil Capacity 2 5 L 2 6 U S qt Overhaul 1 9 L 2 0 U S qt Change Gasoline recommended 87 Octane Regular Unleaded Eng...

Page 5: ...e ft lb N m Engine Mounting Through Bolt Frame 38 52 Front Differential Frame Differential Bracket 38 52 Output Flange Rear Flange Output Joint 20 27 Pinion Housing Differential Housing 23 31 Differen...

Page 6: ...Crankshaft Spacer Crankshaft 25 34 Speed Sensor Housing Crankcase 8 11 Clutch Shoe Crankshaft 221 300 Clutch Cover Housing Assembly Crankcase 8 11 Crankcase Half 6 mm Crankcase Half 8 11 Crankcase Ha...

Page 7: ...asoline Oil Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated ga...

Page 8: ...er and base with a damp cloth and allow it to dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV to dry thoroughly DO NOT get water int...

Page 9: ...all control wires and cables for signs of wear or fraying Replace if necessary 4 Change the engine transmission oil and filter 5 On liquid cooled models check the coolant level and add properly mixed...

Page 10: ...alve Tappet Clearance Valve Adjuster Procedure H2 2 6 Testing Engine Compression 2 6 Spark Plug s 2 7 Muffler Spark Arrester 2 7 Engine Transmission Oil Filter Strainer 2 8 Front Differential Rear Dri...

Page 11: ...k Arrester C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R Carburetor Float Chamber 400 650 D Engine Idle RPM 400 650 I I A Engine Transmission Oil Level I A Engine Transmission Oil Filter R...

Page 12: ...le to lubricate certain components periodi cally to ensure free movement Apply light oil to the components using the following list as reference A Throttle Lever Pivot Cable Ends B Brake Lever Pivot C...

Page 13: ...tion of oil or gas from the filter housing and drains Valve Tappet Clearance Feeler Gauge Procedure To check and adjust valve tappet clearance use the following procedure 1 Remove the timing inspectio...

Page 14: ...e Valve Clearance Adjuster for this pro cedure 3 Place the valve adjuster onto the jam nut securing the tappet adjuster screw then rotate the valve adjuster dial clockwise until the end is seated in t...

Page 15: ...e end is seated in the tappet adjuster screw 4 While holding the valve adjuster dial in place use the valve adjuster handle and loosen the jam nut then rotate the tappet adjuster screw clockwise until...

Page 16: ...Section 3 Spark Plug s A light brown insulator indicates that a plug is correct A white or dark insulator indicates that the engine may need to be serviced or the carburetor if equipped may need to be...

Page 17: ...r plug CF109M GZ415A 3 Remove the drain plug from the bottom of the engine and drain the oil into a drain pan 733 441A 4 Remove the oil filter plug from the filter mounting boss located on the front s...

Page 18: ...Remove the two cap screws securing the strainer then remove the strainer NOTE On the H1 H2 models thoroughly clean any sealant from the oil strainer cap CC163D 4 Place the oil strainer into position b...

Page 19: ...fill plugs NOTE If the differential rear drive lubricant is contaminated with water inspect the drain plug fill plug and or bladder Driveshaft Coupling The following drive system components should be...

Page 20: ...he 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 HIGH beam light zone is to be used f...

Page 21: ...gine 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 the circuit Troubleshoot the harness...

Page 22: ...ys a sufficient amount of brake fluid If low refill the reservoir before the bleeding proce dure is continued Failure to maintain a sufficient amount of fluid in the reservoir will result in air in th...

Page 23: ...brake pads when they show excessive wear Check the thickness of each of the brake pads as follows NOTE As brake pads wear it may be necessary to top off the brake fluid in the reservoir 1 Remove a fr...

Page 24: ...2 Remove the cap screws securing the V belt cover noting the location of the different lengthed cap screws for installing purposes then using a rubber mallet gently tap on the cover tabs to loosen the...

Page 25: ...the driven clutch 4 Place the V belt cover gasket into position then install the cover and secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighte...

Page 26: ...N TABLE OF CONTENTS Engine Transmission 3 2 Specifications 400 3 2 Specifications H1 3 3 Specifications H2 3 3 Troubleshooting 3 4 400 Table of Contents 3 7 H1 Table of Contents 3 48 H2 Table of Conte...

Page 27: ...Valve Guide Stem Clearance max intake exhaust 0 04 mm 0 06 mm Valve Guide Valve Stem Deflection max wobble method 0 35 mm Valve Guide Inside Diameter 5 000 5 012 mm Valve Stem Outside Diameter intake...

Page 28: ...3 021 mm Connecting Rod big end side to side 0 6 mm Connecting Rod 150 mm max small end deflection 0 3 mm Crankshaft web to web 71 mm Crankshaft Runout max 0 03 mm VALVES AND GUIDES Valve Face Diamete...

Page 29: ...3 Clean replace hose 4 Clean replace inlet screen valve screen 5 Replace fuel pump Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit ECU defective 4 Carb...

Page 30: ...wide 8 Ignition coil defective 9 Float out of adjustment 10 Jets obstructed 11 Pilot screw setting improper 12 Fuel injector obstructed 1 Adjust clearance 2 Replace service seats valves 3 Replace gui...

Page 31: ...e injector 10 Adjust float height 11 Clean element 12 Drain excess oil change oil 13 Tighten replace manifold 14 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston cro...

Page 32: ...to elevate the wheels 1 Remove the front rack left and right footwells and front body panel see Section 8 then discon nect the negative battery cable from the battery 2 Remove the heat shield then rem...

Page 33: ...ws securing the exhaust pipe to the cylinder head then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe Account for a grafoil seal and seal ring KC170 KC238 7 Disconnect the...

Page 34: ...d from the frame for this procedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using...

Page 35: ...two cap screws secur ing the cam chain tensioner assembly Remove the tensioner assembly and gasket MD1245 4 Remove the cam chain tensioner pivot cap screw and washer MD1251 5 Bend the washer tabs and...

Page 36: ...1192 9 Remove the four cylinder head cap screws and washers Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left...

Page 37: ...on of each ring for proper installation When replacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence MD1211 A Starting with the top rin...

Page 38: ...nuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Keep all valves and valve components as a set Note the original lo...

Page 39: ...point on the out side edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications Measuring Valve Guide Valve Stem Deflec...

Page 40: ...ings with the closest wound coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor compress the valve springs and install the valve kee...

Page 41: ...end gap Acceptable ring end gap must be within specifications CC995 Measuring Piston Pin Connecting Rod Small End and Piston Pin Bore 1 Measure the piston pin outside diameter at each end and in the c...

Page 42: ...E If the cylinder cylinder head assembly cannot be trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustio...

Page 43: ...sembly by continuing to move the cylin der in a figure eight motion until a uniform bright metallic finish is attained CC997 Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks...

Page 44: ...and note runout maximum tolerance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe height ATV1013A 2 The lobe heights must not exceed minimum spec...

Page 45: ...and unloader pin for damage CF061A NOTE With the weight extended the unloader pin should be flat side out with the weight retracted the unloader pin should be round side out CF060A 2 If damaged the c...

Page 46: ...nuts will be tightened in step 9 MD1226A C Cylinder Head Camshaft D Valve Cover Rocker Arms NOTE Steps 1 4 in the preceding sub section must precede this procedure 5 While keeping tension on the cam c...

Page 47: ...op dead center 11 While holding the cam chain sprocket to the side install the rear cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer CD383 12 With the alignment...

Page 48: ...e cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned 16 Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole MD1363 17 Apply red...

Page 49: ...er and secure with the two cap screws MD1254 24 Install the cap screw and spring into the end of the cam chain tensioner Tighten securely MD1245 25 Loosen the adjuster screw jam nuts then loosen the a...

Page 50: ...cation of the 8 mm cap screw with the washer near the middle of the left side cover Keep the different lengthed 6 mm cap screws in order for installing purposes MD1186 3 Using an appropriate side case...

Page 51: ...68 MD1369 MD1370 7 Remove the starter idler gear No 1 and starter idler gear No 2 MD1305 8 Remove the gear shift shaft assembly and washer from the left side crankcase Note the positions of the alignm...

Page 52: ...talling Left Side Components A Starter Idler Gears B Rotor Flywheel 1 Place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three ca...

Page 53: ...s The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A V Belt Cover B Dri...

Page 54: ...Remove the V belt MD1118 6 Remove the fixed drive face MD1094 7 Remove the nut holding the driven pulley assem bly then remove the driven pulley assembly MD1068 8 Using an impact screwdriver remove th...

Page 55: ...ear G Oil Pump Driven Gear NOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the cap screw holding the gear position switch onto the right side crankcase half KC324A 1...

Page 56: ...il pump driven gear 19 Remove oil pump driven gear Account for the drive pin and thrust washer MD1020 H Oil Pump Oil Strainer NOTE Steps 1 19 in the preceding sub sections must precede this procedure...

Page 57: ...RIFUGAL CLUTCH HOUSING 1 Inspect the clutch housing for burns marks scuffs cracks scratches or uneven wear 2 If the housing is damaged in any way the housing must be replaced INSPECTING PRIMARY ONE WA...

Page 58: ...Oil Pump 1 Place the oil strainer into position beneath the crankcase Tighten the Phillips head screws coated with red Loctite 271 securely MD1337 2 Place the strainer cap into position on the crank...

Page 59: ...left hand thread coated with red Loctite 271 Tighten to 147 ft lb NOTE The flat side of the flange nut should be directed towards the clutch shoe 8 Install the one way clutch making sure that the gre...

Page 60: ...reads of the three Phillips head cap screws then install and tighten securely MD1342 13 Place the driven pulley assembly into position and secure with the nut threads coated with red Loc tite 271 Tigh...

Page 61: ...te the V belt and drive driven assemblies until the V belt is flush with the top of the driven pulley 19 Install two alignment pins and place a new V belt cover gasket into position on the clutch cove...

Page 62: ...keep the shaft gear assemblies intact for identification tap the shafts toward the left side crankcase half when separating the halves MD1313 Disassembling Crankcase Half 1 Remove the secondary and pr...

Page 63: ...assembly Account for inner and outer washers KC325 7 Remove the counterbalance gear Account for the key 8 Remove the counterbalance shaft MD1024 9 Using Crankcase Separator Crankshaft Remover with the...

Page 64: ...sh NOTE If backlash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner...

Page 65: ...dicator and base on the surface plate Position the indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the small end of the connecting rod...

Page 66: ...he circlip 2 Place the sliding dog onto the countershaft then secure with the circlip Place the washer next to the circlip 3 Place the low driven gear onto the countershaft making sure the bearing and...

Page 67: ...e crankshaft so the counterweight is toward the rear of the engine Install the counter balance shaft MD1024 5 Keeping the counterbalance gear timing mark aligned with the one on the crankshaft gear in...

Page 68: ...alves 1 Verify that the two alignment pins are in place and that both case halves are clean and grease free Apply Three Bond Sealant to the mating surfaces Place the right side half onto the left side...

Page 69: ...sticking occurs Installing Engine Transmission 1 From the right side place the engine transmission into the frame tilting the top side forward to clear the frame member KC216 2 Install the front and...

Page 70: ...r silencer into the frame then install the exhaust pipe using a new exhaust pipe seal and grafoil seal Tighten the cap screws evenly to 20 ft lb and install the muffler retainer springs KC237 KC238 KC...

Page 71: ...he shift rod onto the shift arm with bushing and flat washer and secure with an E clip then connect the speedometer sensor plug KC255 KC248 10 Connect the oil temperature connector and cooling fan con...

Page 72: ...tank see Section 4 13 Install the front body panel front rack and foot wells see Section 8 14 Pour the appropriate quantity and grade oil into the crankcase then connect the negative battery cable an...

Page 73: ...e the positive cable Remove the 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...

Page 74: ...ase vent hose from the air filter housing Remove the clamp securing the car buretor intake duct to the air filter housing then remove the air filter housing CD787 CD786 11 Remove the clamp securing th...

Page 75: ...head then remove the pipe CD803 17 Remove the two coolant hoses from the engine then route the hoses out of the way 18 Remove the cap screws securing the rear drive shaft output flange to the rear out...

Page 76: ...wire to the engine KC201A 25 Remove the engine mounting through bolts Account for all mounting hardware CD809 26 Raise the rear of the engine enough to allow the rear output flange to clear the outpu...

Page 77: ...ssed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to removed from the frame for this procedure Removing Top S...

Page 78: ...nt pins CD205 CD206 CD211A 3 Loosen the cap screw on the end of the tensioner then remove the two cap screws securing the ten sioner adjuster assembly and remove the assembly Account for a gasket CC00...

Page 79: ...nder and secure it to keep it from falling into the crankcase 8 Remove the five nuts securing the cylinder head to the cylinder CC017D CC018D CC016D 9 Remove the cylinder head from the cylinder remove...

Page 80: ...CC024D CC025D CC026D 13 Using an awl remove one piston pin circlip CC032D 14 Using the Piston Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston NOTE It is advisa...

Page 81: ...ve the valve cover in a figure eight motion Inspect the sealing surface for any indica tion of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assembly by...

Page 82: ...asuring Valve Face Seat Width 1 Using a micrometer measure the width of the valve face ATV 1004 2 Acceptable width range must be within specifica tions Measuring Valve Face Radial Runout 1 Mount a dia...

Page 83: ...easuring Rocker Arm Shaft Outside Diameter 1 Using a micrometer measure the outside diameter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifications Installing Valves...

Page 84: ...installing new rings install as a complete set only Cleaning Inspecting Piston Rings 1 Take an old piston ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sha...

Page 85: ...ton 5 for correct ring end gap orientation 2 The ring with the orientation mark MTOP or TOP should be installed in the second middle groove and the ring with the orientation mark M or O should be inst...

Page 86: ...rit wet or dry sandpaper Using light pressure move the cylinder in a figure eight motion Inspect the sealing surface for any indica tion of high spots A high spot can be noted by a bright metallic fin...

Page 87: ...cylinder and piston Measuring Camshaft Runout NOTE If the camshaft is out of tolerance it must be replaced 1 Place the camshaft on a set of V blocks then posi tion the dial indicator contact point ag...

Page 88: ...Match the width of the plasti gauge with the chart found on the plasti gauge packaging to determine camshaft to cylinder head and valve cover clear ance CC145D 6 If clearance is excessive measure the...

Page 89: ...e the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crankcase CC024D 4 Loosely install the two nuts which secure the cyl inder t...

Page 90: ...tall the rear cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer NOTE At this point oil the camshaft journals cam lobes and the three seating surfaces on the cylin...

Page 91: ...rst cap screw threads coated with red Loctite 271 securing the sprocket and tab washer to the camshaft Tighten only until snug CD464 19 Rotate the crankshaft until the second cap screw securing the sp...

Page 92: ...adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clock wise The adjuster shaft tension will be released in step 25 24 Place the chain tensioner adjuster assembly and g...

Page 93: ...p 29 to 8 5 ft lb 31 Adjust valve tappet clearance see Section 2 32 Place the two tappet covers into position making sure the proper cap screws are with the proper cover Tighten the cap screws securel...

Page 94: ...r pump then remove the crossover tube from the cylinder head Account for an O ring CD923 6 Remove the two cap screws securing the water pump to the engine then remove the water pump 7 Remove the cap s...

Page 95: ...g the water pump driven gear then remove the gear noting the direc tion of the sides of the gear for installing purposes Account for the driven gear alignment pin CD952A NOTE There is an oil passage b...

Page 96: ...n secure with the snap ring CD950A CD952A CD949 NOTE The sharp side of the snap ring should be facing outward 2 Install the water pump drive gear drive pin and the drive gear with the flat side of the...

Page 97: ...the cap screw threads with red Loctite 271 and tighten securely PR433A CD934 6 Install the shift cam stopper spring and two wash ers then coat the threads on the mounting stud with red Loctite 271 and...

Page 98: ...apply green Loctite 620 to the trigger and countershaft splines and install the trigger Secure with a flat washer and outer snap ring GZ253 GZ254 13 Using a new gasket install the speed sensor hous in...

Page 99: ...cap screws for installing purposes then using a rubber mallet gently tap on the cover tabs to loosen the cover CD079 2 Remove the nut and washer securing the movable drive face then remove the face Ac...

Page 100: ...om the clutch housing Note the location of the green alignment dot or the word OUTSIDE for installing pur poses 9 Using a hydraulic press remove the clutch hous ing assembly from the clutch cover Acco...

Page 101: ...securing the clutch shoe assembly C PR410A 12 Remove the cap screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer CC606 CD987 CD993 13 Using an impact wrench remove...

Page 102: ...es for wear or damage If any shoe is worn to the bottom of the groove replace the complete set ATV1014 INSPECTING CLUTCH HOUSING 1 Inspect the clutch housing for burns grooving cracks or uneven wear 2...

Page 103: ...nstall the secondary shaft bearing housing making sure the two alignment pins are properly posi tioned Tighten the cap screws to 28 ft lb CD999 3 Install the oil pump onto the engine then tighten the...

Page 104: ...cure with the flange nut threads coated with red Loctite 271 Tighten to 221 ft lb PR410A 7 Install the clutch cover alignment pins into the crankcase apply oil to the cover gasket and install the gask...

Page 105: ...then install the air intake plate Tighten the cap screws threads treated with a small amount of red Loctite 271 securely CD971 CD970 13 Place the driven pulley assembly into position and secure with t...

Page 106: ...dures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service o...

Page 107: ...s on the forks for assembling purposes 4 Remove the gear shift shaft G noting the location of the two holes on the end of the shaft Account for two washers PR380A 5 Remove the countershaft assembly D...

Page 108: ...ve bearing housing then remove the nut securing the drive bevel gear shaft in the bearing and using a plastic mallet drive the shaft out of the bearing Account for shim shims NOTE Shims should be meas...

Page 109: ...8A 4 Install a new seal F output yoke G and nut H and tighten to 59 ft lb MT008B NOTE Do not use a new lock nut at this time as this procedure may have to be repeated 5 Place the assembled shaft into...

Page 110: ...ghten the output shaft nut to 59 ft lb and the output yoke nut to 74 ft lb CRANKSHAFT ASSEMBLY NOTE The crankshaft and connecting rod is a non serviceable assembly If any component is out of specifica...

Page 111: ...he reverse driven gear dog then remove the snap ring 3 Remove the reverse driven gear spacer then remove the snap ring 4 In order remove washer reverse driven gear bear ing and bushing 5 In order remo...

Page 112: ...liberal amount of engine oil to the crank shaft bearing Using a propane torch heat the bearing until the oil begins to smoke then slide the crankshaft assembly into place CC688 CC689 NOTE If heating t...

Page 113: ...the left side of the crankcase mak ing sure the bearing locating pins are toward the top of the crankcase and the bearing C ring is fully seated in the crankcase CD268A 11 Place the oil strainer into...

Page 114: ...ng or sticking occurs Installing Engine Transmission NOTE Arctic Cat recommends that new gaskets and O rings be installed whenever servicing the ATV 1 From the left side place the engine transmission...

Page 115: ...th a cap screw Tighten to 8 ft lb CD810 9 Connect the gear shift position switch A stator connector B and the CDI connector C to the main wiring harness CD797A 10 Connect the temperature sensor wire t...

Page 116: ...asline hose connec tor to the fuel rail EFI CD766A FI092E 21 Install the side panels into position 22 Place the battery into position in the battery com partment then install the battery cables and ve...

Page 117: ...this important information Secure the ATV on a support stand to elevate the wheels 1 Remove the seat and tool tray then remove the negative battery cable 2 Remove the front rack gauge pod footwells a...

Page 118: ...bly over the handlebar GZ090B 7 Disconnect the fuel injector wiring connectors then remove the intake manifolds leaving the injectors installed GZ106 GZ107 8 Disconnect the stator coil connector and t...

Page 119: ...e springs securing the rear exhaust pipe to the front exhaust pipe and remove the rear exhaust pipe Account for a grafoil seal on the pipe juncture and a seal in the cylinder GZ099A 14 Remove the fron...

Page 120: ...m Install the bleed screw and radiator drain plug and tighten securely GZ009A 19 Remove the coolant hoses from the upper engine coolant outlet pipes then remove the lower cool ant hose from the water...

Page 121: ...ressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission must be removed to service the rear cylinder head cylin der and piston...

Page 122: ...ead account for the four rubber washers on the top side cap screws Remove the valve cover Account for and note the orientation of the cam shaft plug Note the location of two alignment pins GZ126A GZ16...

Page 123: ...the sprocket and camshaft out of the cylinder head CC266D NOTE Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase 8 Remove the five nuts securing the cylind...

Page 124: ...r hose union to the cylinder then remove the union from the cylinder Account for an O ring GZ140A 12 Remove the two nuts securing the cylinder to the crankcase GZ141A GZ160A 13 Lift the cylinder off t...

Page 125: ...er signs of abnormal wear NOTE Whenever a valve is out of tolerance it must be replaced Cleaning Inspecting Valve Cover NOTE If the valve cover cannot be trued the cyl inder head assembly must be repl...

Page 126: ...e V Blocks then check the valve stem runout using a dial indi cator ATV 1082 2 Maximum runout must not exceed specifications Measuring Valve Stem Outside Diameter 1 Using a micrometer measure the valv...

Page 127: ...de Inside Diameter 1 Insert a snap gauge 1 2 way down into each valve guide bore then remove the gauge and measure it with a micrometer 2 Acceptable inside diameter range must be within specifications...

Page 128: ...spect the perimeter of each piston for signs of excessive blowby Excessive blowby indicates worn piston rings or an out of round cylinder Removing Piston Rings 1 Starting with the top ring slide one e...

Page 129: ...six places CC127D 2 Measure the corresponding piston diameter at a point 15 mm 0 6 in above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measurement in...

Page 130: ...Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion factor between the head and the straightedge 3 Maximum...

Page 131: ...drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly clean cylinder after honing using soap and hot water Dry with comp...

Page 132: ...p screws Tighten securely NOTE Do not rotate the camshaft when measur ing clearance 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve cover and camshaft 5 Match th...

Page 133: ...kirt and square the piston in respect to the crankcase GZ159 3 Lubricate the inside wall of the cylinder then using a ring compressor compress the rings and slide the cylinder over the piston Route th...

Page 134: ...d cap screws from step 8 initally to 20 ft lb then increase to 30 ft lb and finally to 37 ft lb Tighten the 8 mm nut from step 9 to 18 ft lb then using a crisscross pattern tighten the 6 mm nuts from...

Page 135: ...ft sprocket assembly onto the cylinder ensuring the following GZ190B A Piston still at top dead center B Camshaft lobes directed down toward the pis ton C Camshaft alignment marks parallel to the valv...

Page 136: ...parallel with the valve cover mating surface If rotating the camshaft is necessary for alignment do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position GZ...

Page 137: ...ghten to 10 ft lb Bend the tab to secure the cap screw GZ193 CD465 25 Rotate the crankshaft until the first cap screw from step 23 can be addressed then tighten to 10 ft lb Bend the tab to secure the...

Page 138: ...29 Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws CD469 30 Using a flat blade screwdriver rotate the adjuster screw inside the...

Page 139: ...the spark plugs Tighten securely Left Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those compone...

Page 140: ...nut then install the appropriate crankshaft protector into the crank shaft PR440 4 Install Magneto Rotor Remover Set and loosen the rotor flywheel then remove the crankshaft protec tor and rotor flywh...

Page 141: ...that may have come off with the cover Make sure they are returned to their respec tive shafts GZ231A GZ233A 9 Remove the nut A from the shift cam stopper bolt B then remove the cam stopper spring C Ac...

Page 142: ...ll the oil filler cover into the crankcase and secure with the cap screws Tighten to 8 ft lb GZ250 3 Clean the countershaft and trigger splines throughly and install the inner snap ring onto the shaft...

Page 143: ...o the shift cam stopper and secure with a flat washer and flange nut Tighten to 8 ft lb GZ259 7 Install the shift cam plate onto the shift cam shaft and secure with the cap screw Tighten to 8 ft lb GZ...

Page 144: ...ll the starter driven and counter gear shafts D into the crankcase longer shaft to the front then install the starter countershaft gear C starter driven gear A and bushing B making sure the chamfered...

Page 145: ...tch 1 Remove the cap screws securing the V belt cover then using a rubber mallet gently tap on the cover tabs to loosen the cover Account for a gasket and two alignment pins GZ244B 2 Remove the nut se...

Page 146: ...o alignment pins GZ246B GZ247A NOTE To aid in installing it is recommended that the assemblies are kept together and IN ORDER 8 Remove the one way clutch from the centrifugal clutch Note the location...

Page 147: ...bottom of the groove replace the complete set ATV1014 INSPECTING CLUTCH HOUSING 1 Inspect the clutch housing for burns grooving cracks or uneven wear 2 If the housing is damaged in any way the housing...

Page 148: ...and install the gasket onto the crankcase 4 Apply grease to the outer edges of the clutch hous ing then from inside the clutch cover install the clutch housing into the cover 5 Lightly grease the clu...

Page 149: ...cap screw then when the faces are separated insert the belt and push down between the faces GZ065A 12 Place the V belt into position on the driven pulley and over the front shaft GZ085 NOTE The arrow...

Page 150: ...For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment...

Page 151: ...s in this section 4 Remove one cap screw from the right side crank case and eight cap screws from the left side crank case then using a rubber mallet separate the crankcase halves leaving all componen...

Page 152: ...is required If disassembled sec ondary gear sets will have to be reset for backlash and gear contact see Servicing Center Crankcase Components in this section 4 Remove one cap screw from the right si...

Page 153: ...ter pump drive idler B to the idler shaft then remove the drive idler GZ299A 3 Remove the water pump driven shaft C Account for the driven gear and drive pin GZ304A 4 Remove the snap ring securing the...

Page 154: ...ase Components sub sec tion Disassembling Crankcase Half Gen II NOTE For steps 1 8 refer to illustration GZ474A GZ474A NOTE To aid in installing it is recommended that the assemblies are kept together...

Page 155: ...mbly F Account for three flat washers GZ276 6 Remove two cap screws securing the oil pump in the crankcase and remove the oil pump GZ305 7 Remove the driveshaft G then remove the coun tershaft assembl...

Page 156: ...tall the driven gear C on the shaft until the gear firmly seats on the shoulder of the shaft MT011B 3 If installing the existing shaft start with the shims removed during disassembly or if installing...

Page 157: ...existing shim measure it and install a new thinner shim GZ393A 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove m...

Page 158: ...g a feeler gauge check the inner to outer rotor clearance If measurements exceed specifications the gerotor set must be replaced GZ355 4 Inspect the oil pump cover for scoring discolor ation or cracks...

Page 159: ...4 Place a new O ring seal on the outside of the oil pump cover The oil pump assembly is now ready for assembly into the crankcase GZ362 CRANKSHAFT ASSEMBLY NOTE The crankshaft and connecting rod is a...

Page 160: ...t slowly 4 Maximum runout must not exceed specifications NOTE Proceed to check runout on the other end of the crankshaft by positioning the indicator con tact at point 2 and following steps 3 4 Measur...

Page 161: ...riven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer then remove the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear lockin...

Page 162: ...the low driven gear locking washer then install the inner reverse driven gear washer GZ319B GZ320B 3 Install the reverse driven bushing and bearing then install the reverse driven gear GZ286A GZ287 4...

Page 163: ...two drive gear washers and the shift forks The countershaft is now ready for installa tion Assembling Crankcase Half Gen I 1 Install the oil pump gerotor assembly and oil pump cover in the crankcase a...

Page 164: ...nstall the crankshaft assembly into the crankcase GZ330 NOTE It will be necessary to rotate the crank shaft back and forth to engage the teeth of the oil pump and countershaft gears 6 Install the driv...

Page 165: ...ctite 243 and tighten securely to 8 ft lb GZ305 2 Install a flat washer drive pin and drive gear onto the oil pump shaft then secure with a snap ring flat side away from the gear GZ347 3 Install the c...

Page 166: ...he driveshaft then with a flat washer on each end of the reverse idler assembly install into the crankcase GZ332 GZ333 7 Install the gear shift shaft into the crankcase mak ing sure the flat washer is...

Page 167: ...toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of silicone sealant to the crankcase mating surface GZ345A AT THIS POINT Proper transmission shifting should be ver...

Page 168: ...If the secondary drive driven assemblies have been disassembled refer to Servicing Center Crankcase Components for proper gear tooth con tact and backlash 6 Install the locating ring in the crankcase...

Page 169: ...GZ340 2 Coat both sides with motor oil then install the spacer washer on the crankshaft with the radius directed toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of...

Page 170: ...tall 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 GZ269A GZ448A...

Page 171: ...e rear output drive flange and the rear driveshaft yoke flange and install the cap screws Tighten to 20 ft lb 5 Align the engine with the mounting brackets and install the through bolts with flat wash...

Page 172: ...r and connect all exhaust juncture 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 Conn...

Page 173: ...ooling duct and boots 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 section 8 18 Connect the negat...

Page 174: ...hoke 400 650 4 7 Electronic Fuel Injection EFI 4 8 Throttle Cable Free Play 4 10 Engine RPM Idle 4 11 Gas Tank 4 11 Oil Filter Oil Pump 4 12 Testing Oil Pump Pressure 4 12 Oil Cooler 400 700 H2 4 12 L...

Page 175: ...5 Remove the screw securing the throttle actuator cover to the carburetor then remove the cover Description p n Oil Pressure Test Kit 0644 495 Seal Removal Tool 0644 072 Tachometer 0644 275 Electric...

Page 176: ...MBLING 1 Remove the four Phillips head screws securing the top cover then remove the cover CH015D 2 Remove the vacuum piston assembly from the car buretor body Account for a spring spring seat and the...

Page 177: ...ew and remove the idle adjust screw Account for the spring and washer CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Place al...

Page 178: ...washer and spring are properly positioned 2 Install the pilot screw spring washer and O ring CC758 NOTE Turn the pilot screw clockwise until it is lightly seated then turn it counterclockwise the rec...

Page 179: ...Phillips head screws Tighten securely CH015D INSTALLING 1 Connect the gas and vent hoses onto the carbure tor 2 Connect the electric choke lead to the wiring har ness CC740A 3 Place the throttle cable...

Page 180: ...om the carburetor body INSPECTING TESTING 1 Inspect the plunger A for scoring or scratches the needle B for damage to the tip the spring C for breakage and the O ring D for breaks KC328A 2 With the ch...

Page 181: ...er and air fil ter housing cover then remove the air filter 4 Loosen the clamp securing the air filter housing boot to the throttle body inlet then remove the boot from the throttle body FI081B 5 Slow...

Page 182: ...emove the air filter housing from the ATV 4 Disconnect the three wiring connectors from the sensors on the throttle body then remove the cap screws securing the throttle body to the intake manifold GZ...

Page 183: ...s securely in place INSTALLING H2 1 Connect the throttle cable 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 screw...

Page 184: ...etor throttle body by compressing the release on the connector FI092A 4 Remove the cap screws securing the gas tank to the frame 5 Disconnect the fuel gauge connector then remove the gas tank CLEANING...

Page 185: ...chometer to the engine or utilize the LCD if equipped 2 Connect the Oil Pressure Test Kit to the oil pres sure test port H1 or the oil cooler to oil filter line H2 CF264B GZ118A GZ388A NOTE Some oil s...

Page 186: ...d nuts securing the radi ator to the frame 6 Disconnect the fan wiring from the main wiring harness then remove the radiator fan assembly and account for the grommets and collars 7 Remove the fan fan...

Page 187: ...amps for deterioration cracks and wear NOTE All coolant hoses and clamps should be replaced every four years or 4000 miles Installing H1 1 Place the thermostat and O ring into the thermo stat housing...

Page 188: ...ps Tighten securely 3 Place the footrest into position on the frame and loosely secure with four cap screws then secure the front and rear fenders to the footrest with the four torx head cap screws Ti...

Page 189: ...lant drain plug securely then fill the cooling system with appropriate mixed coolant and install the radiator cap 5 Start the engine and check for coolant leaks then add coolant if necessary to proper...

Page 190: ...t out the fuel pump assembly carefully tilting it forward to clear the voltage regulator then guide the pump and float lever through the opening in the gas tank 5 Using duct tape or other suitable mea...

Page 191: ...arily and the fuel gauge indicates the proper fuel level 5 With the transmission in neutral and brake lever lock engaged start the engine and check for nor mal operation Check for any fuel leaks 6 Ins...

Page 192: ...aired Condition Remedy 1 Slow jet obstructed loose 2 Slow jet outlet obstructed 3 Low speed fuel screw setting incorrect 4 Float height incorrect 1 Clean tighten jet 2 Clean outlet 3 Adjust screw 4 Ad...

Page 193: ...gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 TPS out of adjustment 1 Adjust TPS Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out ag...

Page 194: ...stribution Module PDM 5 7 Ignition Coil 5 8 EFI Sensors Components EFI 5 9 Speed Sensor 5 10 Ignition Switch 5 10 Handlebar Control Switches 5 11 Drive Select Switch 5 12 Front Drive Selector Actuator...

Page 195: ...black to black Peak Voltage trigger 7 8 9 3 volts green to blue AC Generator no load Output 60 AC volts 3000 RPM black to black Generator Output approx 220W 5000 RPM 650 Ignition Timing 10 BTDC 1500 R...

Page 196: ...battery to sit for 1 2 hours 9 Connect the multimeter and test the battery volt age The meter should read 12 5 or more DC Volts If the voltage is as specified the battery is ready for service NOTE If...

Page 197: ...itches are acti vated NOTE For absolute accuracy all tests should be made at room temperature of 68 F Accessory Receptacle Connector NOTE This test procedure is for either the recep tacle or the conne...

Page 198: ...resistance RESISTANCE Switch Connector NOTE The brake lever must be compressed for this test Also the ignition switch must be in the OFF position 1 Set the meter selector to the OHMS position 2 Conne...

Page 199: ...hermometer 733 554E 3 On the coolant temperature switch when the oil temperature reaches 112 118 C 234 244 F the meter should read a closed circuit 4 On the coolant temperature switch allow the oil to...

Page 200: ...battery then connect the black wire from the fan connector to the negative side The fan should operate Power Distribution Module PDM The fuses are located in a power distribution module under the sea...

Page 201: ...tests the meter selector should be set to the OHMS position and the primary wire s should be disconnected Primary Winding 1 Connect the red tester lead to either terminal then connect the black tester...

Page 202: ...to the ON position The meter must show battery voltage Primary Voltage ECU H2 NOTE The battery must be at full charge for this test NOTE The ECU is located beneath the rear body panel near the tailli...

Page 203: ...1 Disconnect the three wire connector from the speed sensor harness or from the speed sensor then remove the Allen head cap screw securing the sensor to the sensor housing 2 Remove the sensor from th...

Page 204: ...tch in the HI position the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resistance troubleshoot or replace the switch component the connector or the switch wiring harness...

Page 205: ...n 1 ohm H1 H2 NOTE If the meter does not show as specified replace the front drive selector switch VOLTAGE NOTE The battery must be connected when per forming voltage tests 1 Set the meter selector to...

Page 206: ...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 white green wire in the supply harness The meter must show 0...

Page 207: ...an specified test AC Generator No Load VOLTAGE AC Generator No Load The connector is a three pin one in the harness coming from the generator FI083B NOTE Test the connector that comes from the engine...

Page 208: ...multimeter replace the starter relay If no click is heard and the multimeter con tinues to indicate battery voltage proceed to step 4 4 Disconnect the two wire plug from the starter relay then connect...

Page 209: ...located beneath the seat near the battery H1 or under the fender near the taillight H2 NOTE The ECU is not a serviceable component If the unit is defective it must be replaced The ECU is rarely the ca...

Page 210: ...or to the DC Voltage position 2 Connect the red tester lead to the red blue wire then connect the black tester lead to the black wire 3 With either brake applied the meter must show battery voltage NO...

Page 211: ...s release the reverse override switch and turn the ignition switch to the OFF posi tion then turn the ignition switch to the ON position The display should read AC00 no fault detected NOTE If the LCD...

Page 212: ...olts after approximately one second in the tilted position If the meter readings are not as specified the tilt sensor is defective CD709 NOTE When replacing the sensor after testing make sure the arro...

Page 213: ...red tester lead to the green black wire PR546A 9 Select the DC Voltage position on the meter and turn the ignition switch to the ON position The meter should read approximately 0 60 DC volt with the...

Page 214: ...alf throttle position several times then return the throttle to idle The display should return to B position 7 Remove the test plug then install the left side engine cover Troubleshooting Problem Spar...

Page 215: ...egulator rectifier defective 1 Replace lead wire 2 Replace magneto 3 Replace regulator rectifier Problem Starter button not effective Condition Remedy 1 Battery charge low 2 Switch contacts defective...

Page 216: ...ystem 6 2 Front Drive Actuator Electronic Differential Lock 6 2 Front Differential 6 3 Drive Axles 6 16 Rear Gear Case 6 21 Hub 6 23 Hydraulic Brake Caliper 6 25 Troubleshooting Drive System 6 28 Trou...

Page 217: ...ential Lock NOTE The actuator is not a serviceable compo nent If it is defective it must be replaced NOTE The actuator will operate only when the ignition switch is in the ON position The front drive...

Page 218: ...g the actuator firmly forward tighten the front cap screw to hold the actuator in place then install but do not tighten the two remaining cap screws AG928 4 Loosen the front cap screw then tighten the...

Page 219: ...ver lock NOTE It is not necessary to remove the brake hoses from the calipers for this procedure 7 Remove the two brake calipers Account for the four cap screws AF894D 8 Remove the tie rod cotter pins...

Page 220: ...the A arms AF610D 15 Using a slide hammer remove the front axles AF899D 16 Remove the inner fender panels 17 Using a T 30 torx wrench remove the three screws securing the front drive actuator to the...

Page 221: ...me KX159 Disassembling Input Shaft NOTE This procedure can be performed on a rear gear case however some components may vary from model to model The technician should use discretion and sound judgment...

Page 222: ...aft seal Account for a spacer AF982 6 Remove the snap ring securing the input shaft bearing then place the pinion housing in a press and remove the bearing AF983 AF984 KX219 Assembling Input Shaft 1 P...

Page 223: ...ed grease KX221 KX222 4 Install the input shaft into the pinion housing then install the front boot and secure with an appropri ate boot clamp and the rear boot with an appropri ate boot clamp CD112 C...

Page 224: ...cover in more than one recessed location 4 Remove the splined coupler shifter fork pin and spring of the differential lock assembly and set aside Note position of parts for assembling pur poses KX175...

Page 225: ...use the exist ing shims The numbers are scribed onto the gears the ring gear has the number on the oppo site side of the gears and the pinion gear has the number on the end of the pinion gear shaft b...

Page 226: ...d 4 Prior to final assembling apply molybdenum dis ulfide grease to all oil seal lips 5 Prior to final assembling prelubricate journal on pinion assembly with SAE 80W 90 hypoid gear lubricant prior to...

Page 227: ...n install the gasket CC893 7 Place the pinion housing assembly onto the gear housing then secure with the existing cap screws Tighten to 23 ft lb NOTE If a new gear housing is being installed tighten...

Page 228: ...ctite 609 to 23 ft lb NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new gear case housing is being installed tighten the cap screws to 25 31 ft lb Removing Needle Bearing N...

Page 229: ...the pinion shaft and secure with the existing 48 mm lock collar Tighten to 125 ft lb CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock col...

Page 230: ...on the frame and install the cap screws washers and flex lock nuts Tighten to 38 ft lb Make sure the rubber boot is properly seated on the input yoke CD857 CD859 2 Pour 275 ml 9 3 fl oz of SAE 80W 90...

Page 231: ...th new patch lock cap screws tightened to 20 ft lb AF894D 10 Install the wheels and tighten to 40 ft lb 11 Remove the ATV from the support stand Drive Axles REMOVING REAR DRIVE AXLE 1 Secure the ATV o...

Page 232: ...For removing a front drive axle see Front Differential in this section CLEANING AND INSPECTING NOTE Always clean and inspect the drive axle components to determine if any service or replace ment is n...

Page 233: ...mage is apparent to the splines the bearing ring and or the housing the drive axle must be replaced as an assembly 6 Using a side cutters or suitable substitute remove the small clamp from the shaft C...

Page 234: ...oned correctly NOTE The boot is positioned correctly when the small end of the boot seats down into the recessed groove CD754 2 Using the boot clamp pliers secure the small clamp of the inner boot ATV...

Page 235: ...ghten the hex nut finger tight at this time 4 If the brake calipers were removed position them on the knuckle and secure with new patch lock cap screws Tighten the auxiliary brake caliper cap screws t...

Page 236: ...move the left side rear A arms see Rear A Arms in Section 7 2 Remove both of the rear drive axles see Drive Axles in this section 3 Remove the four cap screws securing the engine output shaft to the r...

Page 237: ...using an appropriate bearing driver press the bearing from the housing GZ184A Cleaning and Inspecting 1 Wash all parts in parts cleaning solvent and dry with compressed air 2 Clean all gasket materia...

Page 238: ...cure with the snap ring flat side directed out ward then install the clutch pack into the basket GZ176 5 Using a new gasket install the assembled rear drive input shaft housing onto the rear drive gea...

Page 239: ...brake 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 hu...

Page 240: ...screw then remove the caliper 4 Compress the caliper holder against the caliper opposite the O ring side and remove the outer brake pad then remove the inner brake pad NOTE If brake pads are to be re...

Page 241: ...excessive wear NOTE For measuring brake pads see Section 2 3 Inspect the brake caliper housings for scoring in the piston bores chipped seal ring grooves or signs of corrosion or discoloration 4 Inspe...

Page 242: ...e brake pads compress the caliper holder toward the cali per and install the inner brake pad then install the outer pad PR238 PR239 6 Place the brake caliper assembly into position and secure with new...

Page 243: ...ial gears pinions broken damaged 7 Sliding dogs shaft fork worn damaged 8 Front drive axle worn damaged 9 Front drive axle serration worn damaged 1 Replace gear s 2 Replace shaft 3 Replace coupling 4...

Page 244: ...7 1 7 SECTION 7 SUSPENSION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 3 Rear A Arms 7 5 Wheels and Tires 7 7 Troubleshooting 7 8 Manual Table of Contents...

Page 245: ...ach AF626D 4 Compress the shock absorber spring remove the retainer and remove the spring AF730D CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacem...

Page 246: ...om the knuckle AF618D 7 Remove the cap screws securing the ball joints to the knuckle AF628D 8 Tap the ball joints out of the knuckle then remove the knuckle 9 Remove the lower shock absorber eyelet f...

Page 247: ...g AF616D 2 Install the A arm assemblies into the frame mounts and secure with the cap screws Only fin ger tighten at this time AF610D 3 Route the brake hose through the upper A arm shock absorber moun...

Page 248: ...l the wheel and tighten to 40 ft lb 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 bra...

Page 249: ...Only finger tighten at this time 2 Slide the knuckle onto the drive axle and into posi tion on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to 35 ft lb 4...

Page 250: ...2 Inspect each wheel for cracks dents or bends 3 Inspect each tire for cuts wear missing lugs and leaks INSTALLING Install each wheel on its hub Tighten to 40 ft lb NOTE Make sure each wheel is insta...

Page 251: ...m Suspension noisy Condition Remedy 1 Cap screws suspension system loose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Rear wheel oscillation Condition Remedy 1 Rear wh...

Page 252: ...Knuckles 8 6 Measuring Adjusting Toe In 8 8 Front Rack 8 9 Front Bumper Assembly 8 9 Front Body Panel Side Panels 8 10 Footrests 8 13 Belly Panel 8 14 Exhaust System 8 14 Rear Body Panel Rack 8 14 Ta...

Page 253: ...s not damaged or missing NOTE Critical torque specifications are located in Section 1 Steering Post Tie Rods REMOVING 1 Remove the ignition switch retaining ring then remove the reinstallable rivets s...

Page 254: ...wo cap screws securing the upper steer ing post bearing to the frame Account for two bearings and two housings CD760 8 Using a suitable lift stand raise the ATV enough to remove the front wheels CD685...

Page 255: ...ear INSTALLING 1 Place the steering post into position then secure the lower bearing flange to the frame with two cap screws Tighten to 20 ft lb AL600D 2 Place the upper steering post bearings into th...

Page 256: ...teering post access cover and secure with four reinstallable rivets then install and secure the radiator access cover FI466A FI465A Handlebar Grip REMOVING 1 Loosen but do not remove the cap screws in...

Page 257: ...hub assembly 6 Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out o...

Page 258: ...tall the hub assembly 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 the two cap screws Tighten to 20...

Page 259: ...easure 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 mea surements are equal then secure the handleb...

Page 260: ...of their normal range of motion and at the correct angle 733 559A Front Rack REMOVING 1 Remove the cap screws and lock nuts securing the rack to the frame and front fender panel 2 Remove the front rac...

Page 261: ...securely Front Body Panel Side Panels REMOVING 1 Remove the reinstallable rivets securing the radia tor access cover and remove the cover then remove four reinstallable rivets securing the steer ing p...

Page 262: ...he 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 axle nut and remove the axle and...

Page 263: ...otate the handlebar to the full left position then place the front body panel over the handlebar and rotate and lower into position CD765 2 Connect the headlight connectors to the appropri ate headlig...

Page 264: ...9 Install the steering post cover and secure with the reinstallable rivets then install and secure the radi ator access panel FI466A FI465A 10 Install the side panels Footrests REMOVING 1 Remove the m...

Page 265: ...ely Exhaust System REMOVING MUFFLER 1 Remove the two exhaust springs at the muf fler exhaust pipe juncture CF138A 2 Slide the muffler rearward to clear the mounting lugs and remove the muffler INSPECT...

Page 266: ...onnector 2 Place 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...

Page 267: ...remove the rear seat pull the two latch handles to the rear and rotate them to the vertical position CF226 2 Lift the rear of the seat up then pull slightly to the rear and lift the seat off the mount...

Page 268: ...acks tears and loose mounting hardware 3 Inspect the box hatch O ring seals for cuts or tears INSTALLING 1 Place the side storage box into position on the frame then secure with the two cap screws A a...

Page 269: ...ct the welds of the cargo box frame for cracking or bending 4 Inspect the cargo box gate latches for smooth operation INSTALLING 1 Place the cargo box into position on the frame Secure with cap screws...

Page 270: ...4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel...

Page 271: ...9 1 9 SECTION 9 CONTROLS INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 3 Shift Lever 9 4 Speedometer Tachometer LCD 9 4 Manual Table of Contents...

Page 272: ...e master cylinder 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 screws securing the...

Page 273: ...the brake lever pivot pin and snap ring BC206 4 Bleed the brake system see Section 2 Throttle Control REMOVING 1 Remove the two machine screws securing the throttle control to the handlebar 2 Slide t...

Page 274: ...1 Place the spring into position between the upper shift arm and shift lever then making sure the O rings are in place on the axle secure the shift lever to the arm with the existing axle and nut 2 P...

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