Arctic Cat 1000 XT 2014 Service Manual Download Page 123

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121

GC011

AF984

KX219

Assembling Input Shaft

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

input shaft bearing. Secure the bearing with the
existing snap ring making sure the sharp edge of the
snap ring faces to the outside.

GC012

GC011

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

seated in the housing.

GC014

3. Lubricate the input shaft with High-Performance #2

Molybdenum Disulphide Grease packing the boot
ribs and splines; then assemble allowing excess
grease to freely escape. Slight pressure on the boot
will be present during assembly. Secure with new
clamps.



NOTE: Any time drive splines are separated, clean

all splines with parts-cleaning solvent and dry with
compressed air; then lubricate with recommended
grease.

GC009A

4. Install the input shaft into the pinion housing and

secure with the snap ring; then install the front boot
and secure with an appropriate boot clamp and the
rear boot with an appropriate boot clamp.

Summary of Contents for 1000 XT 2014

Page 1: ...1000 XT ATV SERVICE MANUAL 2014...

Page 2: ...pecial tools to be completed The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools Arctic Cat...

Page 3: ...ronic Fuel Injection 89 Throttle Cable Free Play 90 Gas Tank 91 Oil Filter Oil Pump 91 Testing Oil Pump Pressure 91 Oil Cooler 92 Liquid Cooling System 92 Electric Fuel Pump Fuel Level Sensor 94 Troub...

Page 4: ...ST COMPONENTS Part Part Bolted To Torque ft lb N m Exhaust Pipe Engine 20 27 Spark Arrester Muffler 48 in lb 5 5 ELECTRICAL COMPONENTS Coil Air Filter Housing 7 10 STEERING COMPONENTS Steering Post Be...

Page 5: ...Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Oil Filler Cover Crankcase 8 11 Speed Sensor Housing Crankcase 8 11 Starter Motor Crankcase 8 11 V Belt Housing Crankcase 8 11 Intake Manifold Cyli...

Page 6: ...asoline expands as its temperature rises the gas tank must be filled to its rated capacity only Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and...

Page 7: ...Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free riding Arctic Cat recommends the following procedure to pre pare the ATV 1 Clean the ATV thoro...

Page 8: ...ce Adjuster 0444 255 Item Initial Service After Break In First Month or 100 Miles Every Day Every Month or Every 100 Miles Every 3 Months or Every 300 Miles Every 6 Months or Every 500 Miles Every Yea...

Page 9: ...oil 9 Clean any dirt or debris from inside the air cleaner 10 Install the air filter frame assembly and cover 11 Install the storage compartment and cover CHECKING AND CLEANING DRAINS 1 Inspect the d...

Page 10: ...ndle with one of the marks on the valve adjuster dial D While holding the valve adjuster handle in place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained...

Page 11: ...mission Servicing Top Side Components 7 Pour 29 5 ml 1 fl oz of oil into the spark plug hole reattach the gauge and retest compression 8 If compression is now evident service the piston rings see Engi...

Page 12: ...ransmission case and allow the filter to drain completely Install the plug and tighten securely 5 Using the adjustable Oil Filter Wrench and a suitable wrench remove the old oil filter NOTE Clean up a...

Page 13: ...ckets may develop therefore run the engine for five minutes after the initial fill shut the engine off and then fill the cooling system to the bot tom of the stand pipe in the radiator neck Checking F...

Page 14: ...Tighten all nuts bolts and cap screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened to...

Page 15: ...evel floor so the headlights are approximately 6 1 m 20 ft from an aiming sur face wall or similar aiming surface ATV 0070C NOTE There should be an average operating load on the ATV when adjusting the...

Page 16: ...An E Error in the gear position icon indi cates no signal or a poor ground wire connection in the circuit Troubleshoot the harness connectors gear position switch connector gear position switch and L...

Page 17: ...ure the cover B Slowly compress the brake pedal several times C Remove the protective cap install one end of a clear hose onto the rear bleeder screw and direct the other end into a container then whi...

Page 18: ...t lb steel wheels or 80 ft lb aluminum wheels 5 Burnish the brake pads Burnishing Brake Pads Brake pads both main and auxiliary must be burnished to achieve full braking effectiveness Braking distance...

Page 19: ...GZ085 INSTALLING 1 Place the V belt into position on the driven pulley and over the front shaft GZ085 NOTE The arrows on the V belt should point in direction of engine rotation forward 2 Pinch the V...

Page 20: ...tch 4 Place the V belt cover gasket into position then install the cover and secure with the cap screws mak ing sure the different lengthed cap screws are in their proper location Tighten the cap scre...

Page 21: ...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 22: ...tabs 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...

Page 23: ...priate 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 c...

Page 24: ...otwells 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 brake...

Page 25: ...Front Body Panel Side Panels in this section 6 Place the seat into position making sure it locks securely LCD Gauge REPLACING To replace the gauge use the following procedure 1 Remove the two reinsta...

Page 26: ...then move the handlebar and gauge out of 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 Us...

Page 27: ...ect 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 for crac...

Page 28: ...compartment steering post and radiator access panels and storage compartment cover then install the shock absorber and tighten to 50 ft lb 7 Install the front wheels and tighten the nuts to 40 ft lb...

Page 29: ...of the throt tle control then remove the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm to the throttle control lever AF677D 4 Remove the a...

Page 30: ...87A PR288 CLEANING AND INSPECTING 1 Clean all knuckle components 2 Inspect the bearing for pits gouges rusting or pre mature wear 3 Inspect the knuckle for cracks breaks or porosity 4 Inspect threads...

Page 31: ...tighten to 40 ft lb steel wheels or 80 ft lb alumi num wheels 12 Remove the ATV from the support stand Measuring Adjusting Toe Out 1 Thoroughly wash the ATV to remove excess weight mud etc 2 Refer to...

Page 32: ...nside rims to the frame tubes should be equal If the measurements are equal proceed to step 8 if the measurements are not equal proceed to step 7 7 To make the measurements equal loosen the appro pria...

Page 33: ...e shift lever to the arm with the existing axle and nut 2 Place the shift rod into position on the shift lever and secure with the existing E clip 3 Check shift lever adjustment see Periodic Mainte na...

Page 34: ...oulder washers securing the belly panel to the underside of the frame then remove the belly panel 2 Place the belly panel into position on the underside of the frame then install the machine screws an...

Page 35: ...d ends 5 Repair replace connections Problem Steering oscillation Condition Remedy 1 Tires inflated unequally 2 Wheel s wobbly 3 Wheel hub cap screw s loose missing 4 Wheel hub bearing worn damaged 5 T...

Page 36: ...max 0 013 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 4 972 4 987 mm Valve Stem Runout max 0 1 mm Valve Head T...

Page 37: ...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 38: ...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 39: ...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 su...

Page 40: ...nect the gear posi tion switch connector GZ069A GZ368A 9 Loosen the clamps securing the V belt cooling ducts to the V belt housing then disconnect the cooling ducts GZ037 GZ103B 10 Remove the E clips...

Page 41: ...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 42: ...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 43: ...onents 68 Center Crankcase Components 72 Separating Crankcase Halves 72 Disassembling Crankcase Half 73 Servicing Center Crankcase Components 74 Assembling Crankcase Half 82 Joining Crankcase Halves 8...

Page 44: ...e 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 the o...

Page 45: ...in 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 in...

Page 46: ...screws securing the water hose union to the cylinder then remove the union from the cylin der Account for an O ring GZ140A 14 Remove the two nuts securing the cylinder to the crankcase GZ141A GZ160A...

Page 47: ...ots before assembly by con tinuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Index all valves springs and cotters...

Page 48: ...lve Face Seat Width 1 Using a micrometer measure the width of the valve face ATV 1004 2 Acceptable widths must be within specifications Measuring Valve Face Radial Runout 1 Mount a dial indicator on t...

Page 49: ...e outside diameter must be at or above spec ifications Installing Valves 1 Apply grease to the inside surface of the valve seals then place a lower spring seat and valve guide seal over each valve gui...

Page 50: ...eed speci fications CC280D Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure the piston pin outside diameter at each end and in the center If measurement exceeds specifica tions the...

Page 51: ...andpaper Using light pres sure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct...

Page 52: ...e cylinder for pitting scoring scuffing and corrosion If marks are found repair the surface using a 320 grit ball hone NOTE To produce the proper 60 cross hatch pat tern use a low RPM drill 600 RPM at...

Page 53: ...secure with the valve cover cap screws Tighten securely NOTE Do not rotate the camshaft when measuring clearance 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve...

Page 54: ...pis ton holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase GZ146B GZ159 3 Lubricate the inside wall of the cylinder then using a ring compressor...

Page 55: ...he four cylinder head cap screws from step 8 initially 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 21 ft lb then using a crisscross pattern tighte...

Page 56: ...toward the piston C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment h...

Page 57: ...euver the camshaft sprocket assembly through the chain and towards its seating position then loop the chain over the sprocket NOTE Note the position of the alignment marks on the end of the camshaft T...

Page 58: ...e camshaft Tighten only until snug GZ195 25 Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed then install the cap screw threads coated with red L...

Page 59: ...en sioner as the adjuster screw is rotated clockwise The adjuster shaft tension will be released in step 30 30 Place the chain tensioner adjuster assembly and gasket into position on the cylinder and...

Page 60: ...rings are properly installed Tighten the cap screws to 9 ft lb GZ208 39 If removed install the spark plugs Tighten securely Left Side Components NOTE For efficiency it is preferable to remove and dis...

Page 61: ...priate crankshaft protector into the crankshaft H2 018 4 Install Magneto Rotor Remover Set and loosen the rotor flywheel then remove the crankshaft protector and rotor flywheel from the crankshaft Acc...

Page 62: ...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 63: ...wheel 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 64: ...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 position then install the crankshaft position sensor...

Page 65: ...ft 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 Ti...

Page 66: ...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 67: ...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 then using a rubber mallet gently tap o...

Page 68: ...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 clutch housing from the clutch cover Account...

Page 69: ...er pump drive shaft and gear assem bly from the engine GZ439 Servicing Right Side Components INSPECTING CENTRIFUGAL CLUTCH SHOES 1 Inspect the clutch shoes for wear chips cracks dam age or discolorati...

Page 70: ...rive pin slot 4 Inspect the drive pin D and driveshaft E for exces sive wear or looseness Assembling 1 Install the bearing in the water pump drive cover and secure with the snap ring flat side away fr...

Page 71: ...nstall the bearing into the clutch cover against the outer bearing face GZ501 NOTE It is critical to verify the seal on the bearing faces the clutch cover seal before pressing in the new bearing 6 Sec...

Page 72: ...ft lb GZ246B 10 Making sure the alignment pins are correctly installed place a bead of silicone sealant on the mating surfaces and install the V belt cover Secure with new patch lock cap screws tight...

Page 73: ...from between the driven clutch faces 16 With the engine in neutral rotate the V belt and clutches counterclockwise until the V belt is flush with the top of the driven clutch 17 Place the CVT cover g...

Page 74: ...rubber hammer free the lower crankcase and remove Account for two alignment pins H2 012B 3 Remove the secondary drive assembly then remove the secondary driven shaft assembly and set aside Account fo...

Page 75: ...locks then carefully remove the crankshaft assembly A from the crankcase GZ298 2 Remove the snap ring securing the water pump drive idler B to the idler shaft then remove the drive idler GZ299A 3 Remo...

Page 76: ...E Do not disassemble the countershaft assem bly unless necessary If necessary see Servicing Center Crankcase Components sub section Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS I...

Page 77: ...nd nut H and tighten to 200 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 the left crankshaft case then lightly co...

Page 78: ...remove measure and install until backlash measurement is within tolerance Note the following chart 3 Once correct gear pattern and backlash are estab lished install a new lock nut coated with red Loct...

Page 79: ...haft and drive pin for excessive wear or grooving Replace as required GZ354A 6 Remove the oil seal from the oil pump cover GZ365 Assembling 1 Install a new oil seal into the oil pump cover then coat t...

Page 80: ...ions Measuring Connecting Rod Small End Deflection 1 Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate Position the indicator contact point against the...

Page 81: ...g the positions for assem bling then remove the high driven gear outer washer high driven gear high driven gear bearing high driven gear bushing and high driven gear inner washer GZ283A 2 Remove the d...

Page 82: ...asher and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer GZ320 GZ319 GZ318A 6 Remove the low driven gear Account for a bearing bushing and thrust washer G...

Page 83: ...0B 3 Install the reverse driven bushing and bearing then install the reverse driven gear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap...

Page 84: ...ecure with two cap screws Coat the threads with red Loctite 271 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 r...

Page 85: ...the gear shift shaft into the crankcase making sure the flat washer is in place on the right case end and the spacer on the gear shift stop end DE677A GZ335 9 Place the larger flat washer on the drive...

Page 86: ...the left side crankcase onto the assembled right side Secure with the cap screws eight left side and one right side GZ342 5 Tighten the 6 mm cap screws to 8 ft lb and the 8 mm cap screws to 20 ft lb...

Page 87: ...halves then secure with the cap screws Tighten the 6 mm cap screws to 8 ft lb and the 8 mm cap screws to 20 ft lb GZ447 10 Install the oil screen then apply a thin bead of silicone sealant to the oil...

Page 88: ...then install the flange nuts and tighten to 45 ft lb 6 Connect the coolant hose and tighten the clamps securely 7 Secure the engine and harness grounds to the engine and tighten the cap screw to 8 ft...

Page 89: ...connector A MAP sensor connector B and ISC valve connector C GZ094A 13 Install the shift linkage with bushings and secure with E clips 14 Connect the gasline hose connectors to the fuel rails then in...

Page 90: ...to frame cap screws see Steering Frame Con trols 18 Connect the negative battery cable then secure the battery with the tool tray and install the seat 19 Pour in the proper quantities of engine trans...

Page 91: ...s tank 4 Verify that the battery is sufficiently charged to crank the engine over at normal speed 5 Check the air filter housing and air filter for contami nation Clean or replace as necessary see Per...

Page 92: ...91A 3 Connect the wiring connector to the IAT sensor 4 Install the front rack and body panel see Steer ing Frame Controls 5 Install the seat making sure it locks securely in place Throttle Cable Free...

Page 93: ...sembly 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 the g...

Page 94: ...he engine for five minutes after the initial fill shut the engine off and then fill the cooling system to the bottom of the stand pipe in the radiator neck RADIATOR Removing 1 Drain the coolant at the...

Page 95: ...C 160 187 F D If the thermostat does not open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear NOTE All coolant hoses and clamps should be repla...

Page 96: ...1 Turn the ignition switch ON and listen for a momen tary whirring sound of the pump building pressure If the sound is heard 10 seconds no electrical checks are necessary Turn the ignition switch OFF...

Page 97: ...free movement The float assembly should return to the lower posi tion without force If not replace the fuel pump assembly 3 Test the fuel level sensor by connecting a multimeter A to the fuel level s...

Page 98: ...dicates the proper fuel level 5 With the transmission in neutral and brake lever lock engaged start the engine and check for normal oper ation Check for any fuel leaks 6 Install any wire ties that wer...

Page 99: ...required by battery drain 800E 1 When charging a battery in the vehicle be sure the ignition switch is in the OFF position 2 Clean the battery terminals with a solution of baking soda and water NOTE...

Page 100: ...outlet NOTE If after charging the battery does not per form to operator expectations bring the battery to an authorized Arctic Cat dealer for further troubleshoot ing RPM Limiter NOTE The ATV is equip...

Page 101: ...lebar Control To access the connector remove the access panel NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Connector 1 Set the meter selector to the DC Voltage position 2...

Page 102: ...er must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance troubleshoot or replace the fan motor NOTE To determine if the fan motor is good con nect the red wire from the fan...

Page 103: ...minal then connect the black tester lead to the other terminal 2 The meter reading must be within specification Secondary Winding 1 Remove the plug cap from the high tension lead then connect the red...

Page 104: ...read approximately 800 ohms 5 On the sensor when the temperature reaches 80 C 176 F the meter should read approximately 318 ohms 6 On the sensor when the temperature reaches 110 C 230 F the meter shou...

Page 105: ...tem 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 volt age regulator weak battery or loose bat tery te...

Page 106: ...power has prevented a suc cessful 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...

Page 107: ...volts to approximately 12 DC volts If meter readings are not as specified A Check EPS diode for correct installation or open diode replace diode or install correctly B Check speed sensor using procedu...

Page 108: ...to the white wire then connect the black tester lead to the gray wire 2 With the dimmer switch in the LO position the meter must show an open circuit NOTE If the meter reads resistance replace the swi...

Page 109: ...or 30 amp fuse and bat tery connections Front Drive Differential Lock Actuator NOTE With the engine stopped and the ignition switch in the ON position a momentary whirring sound must be noticeable eac...

Page 110: ...ading must be within specification RESISTANCE Crankshaft Position Sensor 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the blue wire then connect the black tester lead...

Page 111: ...ter lead to the starter motor ter minal then connect the black tester lead to ground 3 With the starter button depressed the meter must show approximately 10 0 DC volts and the starter motor should op...

Page 112: ...rs LO beam The meter must show battery voltage 4 With the dimmer switch in the HI position test the two inside connectors HI beam The meter must show battery voltage NOTE If battery voltage is not sho...

Page 113: ...volt age is not indicated check wire connections at the ECM or substitute another ECM to verify the test CD706B OUTPUT VOLTAGE NOTE Needle adapters or a break out harness will be required on the mult...

Page 114: ...g or adjusting the TPS will void warranty If the TPS is tested out of specification the throttle body must be replaced If the vehicle is out of warranty the TPS can be adjusted 2 Connect the TPS Multi...

Page 115: ...26 Ignition Coil 2 32 Fuel Injector 1 34 Fuel Injector 2 40 ISC Idle Speed Control Valve 41 Fuel Pump Relay 60 Cooling Fan Relay 95 Sensor Power 96 Incorrect ECM 97 ECM Memory Power constant battery...

Page 116: ...n Remedy 1 Lead wires shorted open loose at terminals 2 Stator coil magneto grounded open 3 Regulator rectifier defective 4 Cell plates battery defective 1 Repair tighten lead wires 2 Replace stator c...

Page 117: ...d 3 Battery short circuited 4 Electrolyte contaminated 1 Check magneto regulator rectifier circuit connections 2 Replace battery correct charging system 3 Replace battery 4 Replace battery Problem Bat...

Page 118: ...is heard see Electrical System Front Drive Dif ferential Lock Actuator If the actuator runs constantly or makes squealing or grinding sounds the actuator must be replaced REMOVING 1 Disconnect the co...

Page 119: ...hten the remaining cap screws then connect the electrical plug to the main harness 6 Turn the ignition switch to the ON position and check the operation by shifting the drive select switch several tim...

Page 120: ...taking care not to strip the threads on the ball joint shaft then using a rubber mallet tap the end of the axle and free it from the knuckle assembly AF628D 11 Pull the steering knuckle away from the...

Page 121: ...ive actuator 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...

Page 122: ...a gasket 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...

Page 123: ...rmance 2 Molybdenum Disulphide Grease packing the boot ribs and splines then assemble allowing excess grease to freely escape Slight pressure on the boot will be present during assembly Secure with ne...

Page 124: ...ng the pinion housing Account for the coupler fork and spring differential only GC015 2 Using a T 40 torx wrench remove the cap screws securing the differential cover Account for and make note of the...

Page 125: ...er assembly Account for shim s and mark as right side KX179 KX181 Disassembling Pinion Gear 1 Remove the internal snap ring securing the pinion bearing in the housing WC430 2 Using the Pinion Gear Sha...

Page 126: ...side directed away from the bearing WC429 Shimming Procedure Shim Selection It is very important to adjust bevel gears for the proper running tolerances Gear life and gear noise are greatly affected b...

Page 127: ...install a thicker shim and recheck GC036A 3 Install the bearing flange onto the gear case cover making sure the alignment locating pin engages the locating hole in the cover then make sure the bear in...

Page 128: ...r case in a holding fixture with the cover side up then install a dial indicator contacting the ring gear axle flange GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator...

Page 129: ...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 130: ...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 131: ...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 132: ...k then while 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 Diff...

Page 133: ...housing INSTALLING REAR DRIVE AXLE 1 Push the axle shaft into the CV cup to release the detent balls then while holding the axle firmly in push the splined shaft end into the gear case PR729C NOTE To...

Page 134: ...er on the steering knuckle using new patch lock cap screws Tighten to 20 ft lb then pump up the hand brake lever and engage the brake lever lock 6 Using an appropriate hub retaining wrench tighten the...

Page 135: ...ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge Clearance should be 0 002 0 004 in GC058A 3 If clearance is as specified remove...

Page 136: ...A Cleaning and Inspecting 1 Wash all parts in parts cleaning solvent and dry with compressed air 2 Clean all gasket material and sealant from mating surfaces 3 Inspect bearings shafts and housing for...

Page 137: ...5 Using a new gasket install the assembled rear drive input shaft housing onto the rear drive gear case and secure with the three cap screws Tighten to 23 ft lb INSTALLING 1 Slide the gear case into p...

Page 138: ...ten the auxiliary cali per to 20 ft lb Tighten the hand brake caliper to 20 ft lb PR243A 6 Using an appropriate hub retaining wrench tighten the hex nut from step 4 to 200 ft lb then install and sprea...

Page 139: ...ebar DE058A INSPECTING 1 Inspect the pin securing the brake lever for wear 2 Inspect the brake lever for elongation of the pivot hole 3 Inspect the reservoir for cracks and leakage 4 Inspect the banjo...

Page 140: ...the chance of vapor lock reducing braking power and increasing stopping distance 3 Remove the brake hose from the caliper and close the bleed screw then remove the caliper 4 Compress the caliper holde...

Page 141: ...ECTING 1 Clean all caliper components except the brake pads with DOT 4 brake fluid Do not wipe dry 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Periodic Mai...

Page 142: ...aliper holder making sure the caliper and holder are correctly oriented NOTE It is very important to apply silicone grease to the O rings and caliper bores prior to assembly PR239C 5 Making sure brake...

Page 143: ...eth broken 2 Propeller shaft serration worn broken 3 Coupling damaged 4 Coupling joint serration worn damaged 5 Front drive driven bevel gears broken damaged 6 Front differential gears pinions broken...

Page 144: ...vate the wheels and to release load on the suspension 2 Remove the two cap screws and nuts securing each front shock absorber to the frame and the upper A arm Account for bushings and sleeves from eac...

Page 145: ...emove the wheels 2 Remove the cotter pin from the nut Discard the cot ter pin CD008 3 Remove the nut securing the hub 4 Remove the brake caliper Account for two cap screws PR377B NOTE Do not allow the...

Page 146: ...n Loctite 609 to the entire outside diame ter of the ball joint Install the ball joint into the A arm and secure with the snap ring AF616D 2 Install the A arm assemblies into the frame mounts and secu...

Page 147: ...ench secure the hub nut from step 9 to the shaft axle Tighten to 200 ft lb NOTE If the cotter pin does not line up always tighten to the next alignment 12 Install a new cotter pin and spread the pin t...

Page 148: ...s into the frame mounts and secure with the cap screws and new lock nuts 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 knuck...

Page 149: ...wheels or 80 ft lb aluminum wheels NOTE Make sure each wheel is installed on its proper hub as noted in removing the rotation arrow if applicable must indicate forward direction of rotation AF612D CH...

Page 150: ...n Condition 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 rela...

Page 151: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 849...

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