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Arctic Cat 2008 366, Service Manual

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Arctic Cat 2008 366 Service Manual Download Page 68

3-40

ATV-0104

Correcting Tooth Contact

„

NOTE: If tooth contact pattern is comparable to

the correct pattern illustration, no correction is
necessary.

If tooth contact pattern is comparable to an incorrect

pattern, correct tooth contact according to the follow-

ing chart.

„

NOTE: To correct tooth contact, steps 1 and 2

(with NOTE) of “Correcting Backlash” must be fol-
lowed and the above “Tooth Contact/Shim Correc-
tion” chart must be consulted.

CRANKSHAFT ASSEMBLY

Measuring Connecting Rod 
(Small End Inside Diameter)

1. Insert a snap gauge into the upper connecting rod

small end bore; then remove the gauge and mea-

sure it with micrometer.

CC290D

2. Maximum diameter must not exceed specifica-

tions.

Measuring Connecting Rod 
(Small End Deflection)

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

mount a dial indicator and base on the surface

plate. Position the indicator contact point against

the center of the connecting rod small end journal.

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

connecting rod away from the dial indicator.

3. Maximum deflection must not exceed specifica-

tions.

Measuring Connecting Rod

(Big End Side-to-Side)

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

side of the crankshaft journal.

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

connecting rod and crankshaft journal.

CC289D

3. Acceptable gap range must be within specifica-

tions.

Tooth Contact

Shim Correction

Contacts at Top

Decrease Shim Thickness

Contacts at Root

Increase Shim Thickness

! CAUTION

After correcting tooth contact, backlash must again
be checked and corrected (if necessary). Continue
the correcting backlash/correcting tooth contact
procedures until they are both within tolerance val-
ues.

Back to TOC

Back to Section TOC

Next

Back

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

www.mymowerparts.com

Summary of Contents for 2008 366

Page 1: ...bol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death The symbol CAUTION identifies unsafe practices which may result in ATV related damage Follow the direc tive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE identifies supplementary informa...

Page 2: ...Section 1 General Information Specifications 2 Periodic Maintenance 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 1 2 3 4 5 6 7 8 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 3: ...fications 1 2 Torque Conversions ft lb N m 1 3 Tightening Torque General Bolts 1 3 Break In Procedure 1 4 Gasoline Oil Lubricant 1 4 Genuine Parts 1 5 Preparation For Storage 1 5 Preparation After Storage 1 5 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 4: ...0 27 Spark Arrester Muffler 48 in lb 5 5 ELECTRICAL COMPONENTS Coil Frame 12 16 Starter Motor Positive Cable Starter Motor 8 11 STEERING COMPONENTS Steering Post Bearing Housing Frame 20 27 Handlebar Cap Steering Post 20 27 Lower Steering Post Bearing Cap Screw Steering Post 40 54 Tie Rod End Steering Post Arm 30 41 BRAKE COMPONENTS Brake Disc Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master C...

Page 5: ...Driven Bevel Gear Nut Driven Shaft 59 80 Hub Nut Shaft Axle max 200 270 Oil Drain Plug Front Differential Rear Drive 45 in lb 5 Oil Fill Plug Front Differential Rear Drive 16 22 Oil Drain Plug Engine 20 27 Wheel Hub 40 54 Rear Drive Gear Case Frame 38 52 Engine Output Flange Rear Gear Case Input Flange 20 27 ft lb N m ft lb N m ft lb N m ft lb N m 1 1 4 26 35 4 51 69 4 76 103 4 2 2 7 27 36 7 52 70...

Page 6: ...octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not neces sary to add a gasoline antifreeze since ethanol will pre vent the accumulation of moisture in the fuel system RECOMMENDED ENGINE TRANSMISSION OIL The recomm...

Page 7: ...o the upper steering post bushing and plungers of the shock absorbers 7 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 8 Turn the gas tank valve to the OFF position 9 Disconnect the battery cables then remove the battery clea...

Page 8: ...all calibrated nuts cap screws and bolts are tightened to specifications 8 Check tire pressure Inflate to recommended pres sure as necessary 9 Make sure the steering moves freely and does not bind 10 Check the spark plug Clean or replace as neces sary CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system CAUTION Connect t...

Page 9: ... Throttle Cable 2 9 Adjusting Engine RPM Idle 2 9 Engine Transmission Oil Filter Strainer 2 9 Front Differential Rear Drive Lubricant 2 11 Tires 2 12 Steering Components 2 12 Driveshaft Coupling 2 12 Suspension Shock Absorbers Bushings 2 12 Nuts Bolts Cap Screws 2 12 Ignition Timing 2 12 Lights 2 13 Shift Lever 2 15 Frame Welds Racks 2 15 Electrical Connections 2 15 Hydraulic Brake Systems 2 15 Bu...

Page 10: ...Float Chamber D Engine Idle RPM I I A Engine Transmission Oil Level I A Engine Transmission Oil Filter R R R Oil Strainer I I C Front Differential Rear Drive Lubricant I I R 4 Yrs Tires Air Pressure I I R Steering Components I I I R V Belt I l R Suspension Ball joint boots drive axle boots front and rear tie rods differential and rear drive bellows I I R Nuts Cap Screws Screws I T A Ignition Timin...

Page 11: ...the battery compartment then thoroughly wash the battery and battery com partment with soap and water NOTE If battery posts cable ends or the battery case has a build up of white green powder residue apply water and baking soda to neutralize acid then flush off with warm soapy water 4 Using a wire brush clean the battery posts and cable ends removing all corrosive buildup Replace damaged cables or...

Page 12: ...ution module in front of the steering post In addition there is a 30 amp fuse on the starter relay under the seat next to the bat tery If there is any type of electrical system failure always check the fuses first NOTE To remove a fuse compress the locking tabs on either side of the fuse case and lift out 0411 837 Air Filter Use the following procedure to remove the filter and inspect and or clean...

Page 13: ... dirt or debris from inside the air cleaner Be sure no dirt enters the carburetor if equipped 7 Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter element straight in the hous ing KC147 8 Install the air filter housing cover and secure with the locking tabs CAUTION A torn air filter element can cause damage to the ATV engin...

Page 14: ...pet adjuster screw until the clearance is within specifications Tighten each jam nut securely after completing the adjustment CC007DC 4 Install the timing inspection plug 5 Place the two tappet covers with O rings into posi tion then tighten the covers securely 6 Install the spark plug then install the timing inspection plug Valve Tappet Clearance Valve Adjuster Procedure To check and adjust valve...

Page 15: ...tighten the covers securely 9 Install the spark plug then install the timing inspection plug Testing Engine Compression To test engine compression use the following proce dure 1 Remove the high tension lead from the spark plug 2 Using compressed air blow any debris from around the spark plug 3 Remove the spark plug then attach the high ten sion lead to the plug and ground the plug on the cylinder ...

Page 16: ... intervals shown in the Periodic Maintenance Chart clean the spark arrester using the following pro cedure 1 Remove the cap screws securing the spark arrester assembly to the muffler then loosen and remove the arrester KC154A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket is damaged in any way it must be replaced...

Page 17: ...sion in neutral start the engine and warm it up to normal operating temperature 2 Turn the idle adjustment screw clockwise one turn past the recommended RPM setting then turn it counterclockwise to 1250 1350 RPM AF920D Engine Transmission Oil Filter Strainer OIL FILTER The engine should always be warm when the oil is changed so the oil will drain easily and completely 1 Park the ATV on level groun...

Page 18: ...ne case NOTE The oil level stick should be threaded into the case for checking purposes 13 Remove the oil level stick the engine oil level should be above the illustrated L mark but not higher than the illustrated F mark ATV 0100AA 14 Inspect the area around the drain plug and oil filter for leaks 15 Install the left side engine cover and the seat STRAINER 1 Remove the belly panel 2 Remove the cap...

Page 19: ...ant use the following procedure 1 Place the ATV on level ground 2 Remove each oil fill plug KC0077A 3 Drain the oil into a drain pan by removing the drain plug from each ATV0082A 737 651B 4 After all the oil has been drained install the drain plugs and tighten to 45 in lb 5 Pour the appropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole 6 Install the fill plugs NOTE I...

Page 20: ...er not cracked broken or missing C Shock absorber body not damaged punctured or leaking D Shock absorber eyelets not broken bent or cracked E Shock absorber eyelet bushings not worn dete riorated cracked or missing F Shock absorber spring not broken or sagging Nuts Bolts Cap Screws Tighten all nuts bolts and cap screws Make sure riv ets holding components together are tight Replace all loose rivet...

Page 21: ... headlight bulb KC146A KC162 2 Press in and release the spring retainer and pull rearward clear of the bulb assembly KC163A 3 Remove the headlight bulb assembly from the headlight housing 4 Install the new headlight bulb into the headlight housing being careful not to get fingerprints or other contaminates on the glass then secure with the spring KC163B 5 Connect the wiring harness connector to th...

Page 22: ...e used for vertical and horizontal aiming 1 Position the ATV on a level floor so the headlights are approximately 6 1 m 20 ft from an aiming surface wall or similar aiming surface ATV 0070C NOTE There should be an average operating load on the ATV when adjusting the headlight aim 2 Measure the distance from the floor to the mid point of each headlight 3 Using the measurements obtained in step 2 ma...

Page 23: ...m nuts securely then shift the trans mission to each position and verify correct adjust ment 4 Install the left side engine cover and seat making sure the seat locks securely in place Frame Welds Racks The frame welds and racks should be checked period ically for damage bends cracks deterioration broken components and missing components If replacement or repair constitutes removal see Section 8 El...

Page 24: ...p C until the brake lever is firm E At this point perform step B C and D on the other FRONT bleeder screw then move to the REAR bleeder screw and follow the same pro cedure 4 Carefully check the entire hydraulic brake system that all hose connections are tight the bleed screws are tight the protective caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydraulic bra...

Page 25: ...ll be extended until brake pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate to 0 5 mph 3 Repeat procedure on each brake system five times 4 Adjust the auxiliary brake if nece...

Page 26: ...ng the V belt to drop down between the pulley faces approximately 3 4 in KC137 5 Pinching the V belt together in front of the driven pulley pull it forward and outward off the clutch shaft then remove it from the driven pulley KC136 6 Inspect the faces of the drive and driven pulleys for scoring pitting cracks or grooving then clean any dirt and debris from the V belt housing and cover INSTALLING ...

Page 27: ...ten to 147 ft lb KC152A KC141 4 Remove the cap screw from the fixed driven face then rotate the pulleys counterclockwise until the driven pulley faces are together 5 With the two alignment pins installed in the V belt housing and a new V belt cover gasket in place install the V belt cover Using the pattern shown secure with the cap screws tightened to 8 ft lb KC142A Back to TOC Back to Section TOC...

Page 28: ...lly onto the pivot stud engaging the master cylinder then secure with the flat washer and cap screw and tighten to 20 ft lb Back to TOC Back to Section TOC Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 29: ...E TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 3 Troubleshooting 3 4 366 Table of Contents 3 7 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 30: ... for clarity purposes only and are not designed to depict actual conditions NOTE Critical torque specifications are located in Section 1 SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section NOTE Special tools are available from the Arctic Cat Service Parts Department Description p n Clutch Sleeve Hub Holder 0444 007 Connecti...

Page 31: ...80 mm 0 6876 0 6882 in Camshaft Runout max 0 03 mm 0 0012 in Rocker Arm Inside Diameter 12 000 12 018 mm 0 472 0 473 in Rocker Arm Shaft Outside Diameter 11 975 11 987 mm 0 4715 0 4719 in Cylinder Head Distortion max 0 05 mm 0 002 in Cylinder Head Cover Distortion max 0 05 mm 0 002 in CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 060 0 073 mm 0 0024 0 0029 in Piston Diameter 15 mm 0 ...

Page 32: ...tive 3 Fuel hose obstructed 4 Fuel screens obstructed 5 Fuel pump defective 1 Clean vent hose 2 Replace valve 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 defective 4 Carburetor jets obstructed 5 Valve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Re...

Page 33: ...aged worn 2 Backlash excessive 3 Tooth contact improper 4 Bearing damaged 5 Gears worn rubbing 6 Splines worn 7 Final driven shaft thrust clearance too large 1 Replace gears 2 Adjust backlash 3 Adjust contact 4 Replace bearing 5 Replace gears 6 Replace shaft s 7 Replace thrust washer s Problem Engine idles poorly Condition Remedy 1 Valve clearance out of adjustment 2 Valve seating poor 3 Valve gui...

Page 34: ...iming incorrect 4 Piston ring s cylinder worn 5 Valve seating poor 6 Spark plug fouled 7 Rocker arms shafts worn 8 Spark plug gap incorrect 9 Carburetor jets obstructed 10 Float level out of adjustment 11 Air cleaner element obstructed 12 Oil in the engine overfilled contaminated 13 Intake manifold leaking air 14 Cam chain worn 1 Adjust clearance 2 Replace springs 3 Re time valve gear 4 Replace se...

Page 35: ...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 remove the gas tank see Section 4 3 Remove the oil fittings from the engine and account for two O rings then disconnect the oil temperature connector and cooling fan connector KC251 KC250 KC249 4 Disconnect the speedometer sensor then rem...

Page 36: ...he 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 gear shift position switch starter cable and engine ground cable then disconnect the trigger coil and stator coil connectors KC228A Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 ...

Page 37: ...o removed from the frame for this procedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appropriate wrench rotate the crankshaft to top dead center of the compression stroke NOTE Arctic Cat recommends the use of new gaskets lock nuts and seals and lubricating all internal com...

Page 38: ...ns CF007A MD1354A 3 Loosen the cap screw on the end of the cam chain tensioner then remove the 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 remove the two cap screws securing the sprocket to the camshaft MD1136 MD1137 Back to TOC Back to Section...

Page 39: ...n remove the two lower nuts securing the cylinder head to the cylinder one in front and one in rear MD1192 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 spark plug side CD211 10 Remove the cylinder head from the cylinder remove the gasket and account ...

Page 40: ...19 NOTE Support the connecting rod with rubber bands to avoid damaging the rod or install a con necting rod holder NOTE If the existing rings will not be replaced with new rings note the location of each ring for proper installation When replacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence AT THIS POINT To service cylinder see Ser...

Page 41: ... by a bright metallic finish Correct any high spots before assembly by continuing 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 location of each valve set for use during installation Return each valve set to its original location during installation 1 Us...

Page 42: ...ng a micrometer measure the width of the valve face ATV 1004 2 Acceptable width must be at or above specifica tions Measuring Valve Face Radial Runout 1 Mount a dial indicator on the surface plate then place the valve stem on a set of V blocks 2 Position the dial indicator contact point on the out side edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Max...

Page 43: ...utside Diameter 1 Using a micrometer measure the outside diameter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifications Installing Valves 1 Apply grease to the inside surface of the valve seals then place a lower spring seat and valve guide seal over each valve guide CC144D 2 Insert each valve into its original valve location 3 Install the valve springs with the...

Page 44: ...e an old piston ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge 2 Using the sharpened ring as a tool clean carbon from the ring grooves Be sure to position the ring with its tapered side up Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cy...

Page 45: ... the let ter s on the top surface of each ring faces the dome of the piston Rotate the rings until the ring end gaps are on directly opposite sides of the pis ton according to the illustration NOTE The chrome silver ring should be installed in the top position MD1343A CYLINDER CYLINDER HEAD ASSEMBLY NOTE If the cylinder cylinder head assembly cannot be trued they must be replaced Cleaning Inspecti...

Page 46: ...t 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 finish Correct any high spots before assembly 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 47: ...exceeds the limit bore the cylinder and install an oversized piston or replace the cylinder NOTE Oversized piston and rings are available The oversized piston and rings are marked for identification ATV 1068A 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 against the sh...

Page 48: ...o the cylinder then remove the valve cover and camshaft MD1261 5 Match the width of the plasti gauge with the chart found on the plasti gauge packaging to determine camshaft to cylinder head and valve cover clear ance CC145D 6 If clearance is excessive measure the journals of the camshaft CC287D NOTE If the journals are worn replace the cam shaft then measure the clearance again If it is still out...

Page 49: ... the rings until the ring end gaps are on directly opposite sides of the piston according to the illustration NOTE The chrome silver ring should be installed in the top position MD1343A 1 Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip is directed upwards or down wards NOTE The piston should be installed so the arrow points towar...

Page 50: ...w gasket into position on the cylinder Place the alignment pins into position then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity MD1347 MD1163 7 Install the four cylinder head cap screws with 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 ...

Page 51: ...n the camshaft sprocket are parallel with the valve cover mating surface NOTE When the camshaft assembly is seated make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket 13 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the camshaft lobes onto the camshaft and place it into position with the cam chain...

Page 52: ...te 271 Tighten to 11 ft lb then bend the tab to secure the cap screw MD1137 19 Rotate the crankshaft until the first cap screw from step 17 securing the sprocket to the cam shaft can be addressed then tighten to 11 ft lb Bend the tab to secure the cap screw 20 Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards 21 Remove the cap screw from the ...

Page 53: ...snug MD1261 28 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 27 to 8 ft lb 29 Adjust valve tappet clearance see Section 2 30 Place the two tappet covers with O rings into posi tion then install and tighten the cap screws securely MD1264 31 Install the spark plug and tighten to 8 ft lb then install the timing inspection plug Left Side Componen...

Page 54: ...mbly Account for the two alignment pins and the posi tion of the shifter bracket for installing purposes CC946 MD1188 NOTE Inspect the inside of the left side cover for any shaft washers that may have come off with the cover Make sure they are returned to their respec tive shafts and that the starter idler gear spacer is on the shaft or in the cover B Rotor Flywheel C Starter Motor NOTE Steps 1 3 ...

Page 55: ...on MD1239 9 Remove the shift detent cam Note position of spacer for installing purposes 10 Remove the cam stopper assembly 11 Remove two starter motor cap screws KC217 12 Remove starter motor by tapping lightly with a mallet NOTE The starter motor is a non serviceable component and must be replaced as an assembly 13 Using an impact screwdriver remove the three Phillips head screws holding the cran...

Page 56: ... No 1 MD1305 7 Place the key into its notch then slide the rotor flywheel with the ring gear in place over the crankshaft Tighten the nut to 107 ft lb C Cover NOTE Steps 1 7 in the preceding sub section must precede this procedure 8 Install two alignment pins and place the left side cover gasket into position Install the left side cover Noting the different lengthed 6 mm cap screws the position of...

Page 57: ...utch cover then slide the brake pedal out ward and remove the V belt cover Account for two alignment pins and a gasket KC142A 3 Mark the movable drive face and the fixed drive face for installing purposes then remove the nut holding the movable drive face onto the crank shaft MD1033 4 Remove the movable drive face and spacer Account for the movable drive face rollers and outer drive face cover MD1...

Page 58: ...o the right side crankcase half Note the posi tions of the different lengthed cap screws for installing purposes 10 Using a rubber mallet loosen the clutch cover then pull it away from the right side crankcase half Account for two alignment pins and gasket MD1115 D Gear Shift Position Switch E Centrifugal Clutch Assembly F Oil Pump Drive Gear G Oil Pump Driven Gear NOTE Steps 1 10 in the preceding...

Page 59: ...TSIDE for installing purposes MD1286 14 Remove the left hand threaded nut holding the centrifugal clutch assembly MD1014 MD1016 15 Remove the cam chain MD1335 16 Remove the oil pump drive gear cap screw MD1018 17 Remove oil pump drive gear Account for the pin CAUTION Care must be taken when removing the nut it has left hand threads Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCO...

Page 60: ...e oil pump Account for two alignment pins MD1060 21 Remove the four cap screws securing the oil strainer cover then remove the Phillips head screws securing the oil strainer Account for the O ring NOTE Note the directional arrow for installing purposes MD1207 AT THIS POINT To service clutch components see Servicing Right Side Components sub section AT THIS POINT To service center crankcase compone...

Page 61: ...t is inadvisable to remove the screw securing the pump halves If the oil pump is damaged it must be replaced NOTE The oil pump is a non serviceable compo nent and must be replaced as a complete assem bly DRIVEN PULLEY ASSEMBLY NOTE The driven pulley assembly is a non ser viceable component and must be replaced as a complete assembly Installing Right Side Components A Oil Strainer Oil Pump 1 Place ...

Page 62: ...b MD1017 MD1018 7 Install the clutch shoe assembly on the crankshaft then install the flange nut left hand thread coated with red Loctite 271 Tighten to 147 ft lb NOTE The flat side of the flange nut should be directed towards the clutch shoe 8 Install the one way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase MD1286 9 Install gear shift position swit...

Page 63: ... the clutch cover cap screws to 8 ft lb MD1117 12 Install the air intake plate Apply red Loctite 271 to the threads of the three Phillips head cap screws then install and tighten securely MD1342 13 Place the driven pulley assembly into position and secure with the nut threads coated with red Loc tite 271 Tighten to 147 ft lb MD1068 KC134 Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV...

Page 64: ...rew can be removed from the driven pulley face 18 Rotate 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 cover Install the V belt cover noting the position of the long cap screws and rubber washer and two wire forms In a crisscross pattern tighten cap scr...

Page 65: ...act for identification tap the shafts toward the left side crankcase half when separating the halves MD1313 Disassembling Crankcase Half 1 Remove the secondary and primary driveshaft assemblies Account for the bearing alignment C ring on the bearing boss next to the pinion gear MD1317 NOTE Note the location of the bearing alignment pin on the secondary output shaft 2 Remove the reverse idler gear ...

Page 66: ...unt 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 remove the crankshaft MD1330 CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary If the shaft is removed the shaft nut must be replaced with a new one and the shaft must be re shimmed Bac...

Page 67: ...within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart Che...

Page 68: ... 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 away from the dial indicator 3 Maximum deflection must not exceed specifica tions Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 ...

Page 69: ...ing the sliding dog Remove the sliding dog 5 Remove the high driven gear circlip then remove the high driven gear Account for the washer bushing and bearing Assembling 1 Place the high driven gear onto the countershaft making sure the bearing bushing and washer are properly positioned Secure with the circlip 2 Place the sliding dog onto the countershaft then secure with the circlip Place the washe...

Page 70: ...ng Using a propane torch heat the bearing until the oil begins to smoke then slide the crank shaft assembly into place MD1334 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft installer 4 Rotate the crankshaft so the counterweight is toward the rear of the engine Install the counter balance shaft MD1024 5 Keeping the counterbalance gear timing mark alig...

Page 71: ... shift fork shaft MD1327 9 Install the input driveshaft MD1326 10 Install the washer spacer sleeve and reverse idler gear MD1357 11 Install the secondary and primary driveshaft assemblies Account for the bearing alignment C ring on the bearing boss next to the pinion gear NOTE Align the bearing alignment pin on the secondary output shaft MD1316 Back to TOC Back to Section TOC Next Back FOR ARCTIC ...

Page 72: ...htening the cap screws CC871 5 In a crisscross case to case pattern tighten the 8 mm cap screws until the halves are correctly joined then tighten to 21 ft lb NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs 6 In a crisscross case to case pattern tighten the 6 mm cap screws to 10 ft lb NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs Instal...

Page 73: ... position switch connectors then attach the engine ground cable and starter cable and secure with cap screws and nuts Tighten to 8 ft lb KC228A KC228B 6 Set the inlet air 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 Back to TOC Back to Section TOC Next Ba...

Page 74: ...buretor boot and tighten all hose clamps securely KC254 9 Install the 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 connector then using new O rings install the oil fittings onto the crankcase and secure with the cap screws Tighten to 8 ft lb Back to T...

Page 75: ... 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 and move the ATV outside to a well ventilated area 15 Start the engine and allow the engine to warm up while checking for oil leaks then shut the engine off and check the oil level Add oil as required Back to TOC Back to Sec...

Page 76: ...cations 4 2 Carburetor Schematic 4 2 Carburetor 4 2 Throttle Cable Free Play 4 8 Engine RPM Idle 4 8 Gas Tank 4 8 Oil Filter Oil Pump 4 10 Testing Oil Pump Pressure 4 10 Oil Cooler 4 11 Troubleshooting 4 12 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 77: ...re Test Kit 0644 495 Seal Removal Tool 0644 072 Tachometer 0644 275 ITEM Carburetor Keihin CVK34 Main Jet 112 Slow Jet 35 Pilot Screw Setting turns 2 3 4 Jet Needle NLGB Idle RPM engine warm 1250 1350 Starter Jet 75 Float Height 17 mm Throttle Cable Free Play at lever 3 6 mm 1 8 1 4 in WARNING Whenever any maintenance or inspection is per formed on the fuel system during which there may be fuel le...

Page 78: ...r can now be removed for service KC258A DISASSEMBLING 1 Remove the four Phillips head screws securing the top cover then remove the cover KC0019A 2 Remove the vacuum piston assembly from the car buretor body Account for a spring spring seat and the jet needle KC0021A 3 Remove the three screws securing the pump hous ing Account for the diaphragm assembly spring and U ring in the housing Back to TOC...

Page 79: ...NOTE Note the locations of the jets pilot screw and holder for disassembling procedures CC761A 7 Secure the needle jet holder with a wrench then remove the main jet 8 Remove the needle jet holder then remove the needle jet slow jet and the starter jet 9 Remove the pilot screw Account for a spring washer and an O ring KC0028A Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PAR...

Page 80: ...t screw and the needle jet for wear damage or distortion 10 Inspect the slow jet and main jet for obstructions or damage NOTE If the slow jet is obstructed the mixture will be extremely lean at idle and part throttle oper ation 11 Inspect the float valve for wear or damage 12 Inspect the carburetor mounting flange for damage and tightness ASSEMBLING 1 Thread the idle adjust screw into the carburet...

Page 81: ... the carburetor with the float pin KC0024 NOTE Check float height by placing the carbure tor on its side w float contacting the needle then measure with a caliper the height when the float arm is in contact with the needle valve Float arm height should be 17 mm KC0035 6 Place the float chamber into position making sure the O ring is properly positioned then secure with the Phillips head screws KC0...

Page 82: ...TALLING 1 Connect the vent hose to the carburetor then con nect the electronic choke connector and install the throttle cable onto the throttle arm KC264A KC263 2 Adjust the throttle cable free play to specifications see Section 2 then tighten the jam nut securely and install the throttle arm cover CAUTION It is important to press down on the pump housing until it contacts the carburetor to make s...

Page 83: ...2 Engine RPM Idle To adjust the idle RPM see Section 2 Gas Tank REMOVING 1 Turn the gas tank valve to the OFF position then remove the seat and side panels 2 Remove the cap screws A securing the rear of the front body to the frame then remove two rein stallable rivets B securing the gas tank cover to the body WARNING Whenever any maintenance or inspection is made on the fuel system during which th...

Page 84: ...s tank to the rear Account for the heat shield KC260 KC262 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all gas tank components with parts cleaning solvent 2 Inspect all hoses for cracks or leaks 3 Inspect tank cap and tank for leaks holes and damaged threads INSTALLING 1 Using a block to hold the front body open pl...

Page 85: ... KC219A 5 Install the side panels and seat making sure it locks securely in place Turn the gas tank valve to the ON position and check for leaks Oil Filter Oil Pump NOTE Whenever internal engine components wear excessively or break and whenever oil is con taminated the oil pump should be replaced The oil pump is not a serviceable component Testing Oil Pump Pressure 1 Connect the Tachometer to the ...

Page 86: ... necessary to drain the engine oil for this procedure 1 Remove the input and output hoses from the fit tings on the cooler 2 Remove the cap screws securing the oil cooler to the frame Account for grommets AL651D 3 Remove the oil cooler from the frame INSTALLING 1 Place the cooler into position in the frame 2 Secure the cooler to the frame with the cap screws and grommets 3 Install the hoses onto t...

Page 87: ...d impaired Condition Remedy 1 High RPM cut out against RPM limiter 2 Main jet obstructed 3 Needle jet obstructed 4 Vacuum piston not operating properly 5 Filter obstructed 6 Float height incorrect 1 Shift into higher gear decrease RPM speed 2 Clean main jet 3 Clean needle jet 4 Check piston operation 5 Clean filter 6 Adjust float height Problem Overflow and fuel level fluctuations Condition Remedy...

Page 88: ... Speed Sensor 5 6 Ignition Switch 5 6 Handlebar Control Switches 5 7 Front Drive Selector Switch 5 7 Front Drive Selector Actuator 5 8 Gear Shift Position Switch 5 8 Stator Coil 5 9 Starter Relay 5 9 Starter Motor 5 10 CDI Unit 5 10 Regulator Rectifier 5 11 Neutral Start Front Drive Actuator Start in Gear 2WD Relays 5 11 Headlights 5 11 Taillights Brakelights 5 11 Running Lights 5 12 Back Up Light...

Page 89: ...ppropriate switches 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 connector VOLTAGE 1 Turn the ignition switch to the ON position then set the meter selector to the DC Voltage position 2 Connect the red tester lead to the red wire then connect the black test...

Page 90: ...he switch Oil Temperature and Cooling Fan Switches 1 Connect the meter leads selector in the OHMS position to the switch contacts 2 Suspend the switch and a thermometer in a con tainer of cooking oil then heat the oil NOTE Neither the switch nor the thermometer should be allowed to touch the bottom of the con tainer or inaccurate readings will occur Use wire holders to suspend switch and thermomet...

Page 91: ...r or the switch wiring harness NOTE To determine if the fan motor is good connect the blue wire from the fan connector to the positive side of a 12 volt DC power supply then connect the black wire from the fan connector to the negative side The fan should operate Fuse Block Power Distribution Module The fuses are located in a power distribution module PDM in front of the steering tube If there is ...

Page 92: ...meter reading must be within specification Secondary Winding 1 Remove the plug cap from the high tension lead then connect the red tester lead to the high tension lead 2 Connect the black tester lead to ground 3 The meter reading must be within specification NOTE If the meter does not show as specified replace ignition coil Spark Plug Cap 1 Connect the red tester lead to one end of the cap then co...

Page 93: ...d see Sec tion 9 To replace a speed sensor use the following proce dure 1 Disconnect the three wire connector from the speed sensor then remove the cap screw securing the sensor to the sensor housing 2 Remove the sensor from the sensor housing accounting for an O ring 3 Install the new speed sensor into the housing with new O ring lightly coated with multi purpose grease then secure the sensor wit...

Page 94: ...er tester lead to the white 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 switch RESISTANCE Emergency Stop 1 Set the meter selector to the OHMS position 2 Connect the one lead to the brown lavender wire then connect the other tester lead to the black white wire 3 With the switch in the OFF position the meter must...

Page 95: ... for this procedure VOLTAGE 1 Select the 2WD position on the front drive selector switch then disconnect the connector on the actu ator wiring harness 2 With the ignition switch in the OFF position con nect the black tester lead to the black wire in the supply harness then connect the red tester lead to the brown lavender wire in the supply harness 3 Turn the ignition switch to the ON position The...

Page 96: ...ree black wires for a total of three tests 3 The meter reading must be within specification RESISTANCE Trigger Coil 1 Disconnect the gray four pin connector on the right side of the engine just above the starter motor 2 Set the meter selector to the OHMS position 3 Connect the red tester lead to the green wire then connect the black tester lead to the blue wire The meter reading must be within spe...

Page 97: ... If the meter showed correct voltage but the starter did not operate or operated slowly the starter motor is defective NOTE If the meter showed no voltage inspect ground connections starter motor lead battery voltage at the battery starter relay or the neutral start relay REMOVING 1 Disconnect the battery 2 Remove the nut securing the positive cable to the starter then remove the cable from the st...

Page 98: ...in type located on the power distribution module Relay function can be checked by switching relay positions The relays are interchangeable NOTE The module and wiring harness are not a serviceable component and must be replaced as an assembly Headlights The connectors are the two 4 pin ones snapped onto the front body rack support To release the connectors from the frame press the release tab with ...

Page 99: ...of the meter to the black wire then with the tester in the DC Volts position connect the red tester lead to the brown black wire 3 Turn the ignition switch to the LIGHTS position The meter must show battery voltage NOTE If the meter does not show voltage inspect the LIGHTS fuse battery connections or troubleshoot the main wiring harness Back Up Lights The back up lights connectors are located on t...

Page 100: ...roken 1 Adjust carburetor 2 Adjust carburetor 3 Change to correct gasoline 4 Clean element 5 Replace plug 6 Replace seals 7 Replace rings Problem Spark plug electrodes overheat or burn Condition Remedy 1 Spark plug incorrect too hot 2 Engine overheats 3 Spark plug loose 4 Mixture too lean 1 Replace plug 2 Service cooling system 3 Tighten plug 4 Adjust carburetor Problem Magneto does not charge Con...

Page 101: ...sulfation Acidic white powdery substance or spots on surfaces of cell plates Condition Remedy 1 Charging rate too low too high 2 Battery electrolyte insufficient 3 Specific gravity too low 4 Battery run down damaged 5 Electrolyte contaminated 1 Replace battery 2 Keep electrolyte to prescribed level 3 Charge battery add distilled water 4 Replace battery 5 Replace battery Problem Battery discharges ...

Page 102: ...ctuator 6 2 Front Differential 6 3 Drive Axles 6 14 Rear Gear Case 6 18 Hub 6 19 Hydraulic Brake Caliper 6 20 Troubleshooting Drive System 6 22 Troubleshooting Brake System 6 22 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 103: ...e it must be replaced NOTE The actuator will operate only when the ignition switch is in the ON position The front drive actuator is located on the side of the front drive input housing With the engine stopped and the ignition switch in the ON position a momentary whirring sound can be heard each time the front drive selector switch is shifted If no sound is heard see Section 5 If the actuator run...

Page 104: ...rew then tighten the cap screw on the driveshaft side AG926 NOTE It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator 5 Tighten the remaining cap screws then connect the electrical plug to the main harness 6 Turn the ignition switch to the ON position and check the operation by shifting the selector switch several times 7 Secure the wiring h...

Page 105: ...k ing care not to damage the seals as the axle clears the knuckle KC314 10 Support the axle to not allow it to drop or hang 11 Using a slide hammer remove the front axles KC289 12 Remove the cap screws from the drive coupler flange then remove the upper and lower mounting cap screws and remove the differential from the frame CAUTION Apply pressure to hold the ball joint firmly in the knuckle or th...

Page 106: ...the fork collar and spring Note the location of all the components for assembling purposes CD103 CD106 3 Using a side cutter or suitable substitute remove the boot clamps then remove the boots and splined drive from the input shaft 4 Remove the input shaft from the pinion housing CD107 5 Using a seal removal tool remove the input shaft seal Account for a spacer AF982 6 Remove the snap ring securin...

Page 107: ...he input shaft seal making sure it is flush with the edge of the housing 3 Lubricate the input shaft splines with High Perfor mance 2 Molybdenum Disulphide Grease NOTE Any time drive splines are separated clean all splines with parts cleaning solvent and dry with compressed air then lubricate with rec ommended grease KX221 Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS...

Page 108: ...g Pinion Gear NOTE This procedure can be performed on a rear gear case 1 Remove the cap screws securing the pinion hous ing Account for the coupler fork and spring KX209 2 Remove the cap screws securing the gear case cover Account for and make note of the ID tag location for assembling purposes KX173 3 Using a plastic mallet tap lightly to remove the differential cover Account for an O ring NOTE I...

Page 109: ... the lock collar has right hand threads On a rear gear case the lock collar has left hand threads CC875 CC876 7 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing CC878 8 Secure the pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar and a bearing CC879 Back to TOC Back to Section TOC Next Back FOR A...

Page 110: ...lue A on the gear case hous ing to value B on the gear case cover then add 1 5 mm This will give you the proper shim thickness B Gear Case Side install a 1 3 1 4 mm shim and tighten the bolts to 25 31 ft lb Verify backlash to be within a range of 0 28 0 38 mm 0 011 0 015 in and end play to be within a range of 0 10 0 20 mm 0 004 0 008 in If not within specification range reselect shim until backla...

Page 111: ...r will remain securely tightened CC891 5 Install the shift fork shaft w spring into the gear housing making sure the shaft O ring is positioned to the inside CC892 6 Install the shift fork assembly making sure the fork leg is facing upward Apply a small amount of oil to the gasket then install the gasket CC893 7 Place the input shaft housing assembly onto the gear housing then secure with the exis...

Page 112: ...d on the gear case cover assembly install the cover with existing hardware Account for the ID tag Tighten the cap screws 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 NOTE Removing the needle bearing is rarely necessary Avoid removing the needle bearing unl...

Page 113: ...using CC889 3 Install 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 collar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear ...

Page 114: ...site side INSTALLING DIFFERENTIAL 1 Align the input flange with the front output flange then place the differential into position on the frame and install the cap screws and nuts Tighten to 38 ft lb KC291A 2 Install the cap screws securing the flange couplers together and tighten to 20 ft lb AG925 3 Install the front axles see Drive Axles in this sec tion CAUTION Make sure the tool is free of nick...

Page 115: ... lever lock 5 Remove the brake caliper right side only NOTE Do not allow the brake caliper to hang from the hose 6 Slide the hub off the shaft and set aside 7 Remove the cap screw and lock nut securing the knuckle to the upper A arm Discard the lock nut KC284 NOTE Never reuse a lock nut Once a lock nut has been removed it must be replaced with a new lock nut 8 While holding the drive axle stationa...

Page 116: ...E If a boot is damaged in any way it must be replaced with a boot kit 3 Inspect the gear case seals for nicks or damage DISASSEMBLING AXLES 1 Using a side cutters or suitable substitute remove the large clamp from the boot CD020 2 Wipe away excess grease to access the retaining ring Using an awl remove the circlip CD021 3 Using a snap ring pliers remove the snap ring securing the bearing ring to t...

Page 117: ...boot ATV 1052 NOTE Grease Pack contains 120 grams of grease The inside joint double offset requires approximately 70 90 grams of grease and the out side bell type requires approximately 35 55 grams When replacing boots use 2 3 of the pack for inside boots and 1 3 of the pack for outside boots 9 Slide the new outside boot onto the shaft with the new clamps positioned as shown Note the differ ent si...

Page 118: ...snap ring faces away from the boot CD023 6 Making sure the marks made during disassembling align slide the housing over the bearing ring then completely seat the bearing ring into the housing and install the circlip NOTE Pull the bearing ring out of the housing until it contacts the circlip then slide the ring in half way This will purge air from the housing and ensure the bearing is packed proper...

Page 119: ...40 ft lb 8 Remove the ATV from the support stand and release the brake lever lock INSTALLING FRONT DRIVE AXLE 1 Position the drive axle in the gear case and steer ing knuckle then insert the upper A arm ball joint into the steering knuckle Secure with a cap screw tightened to 35 ft lb 2 Slide the hub w brake disc into position in the steering knuckle followed by a washer and hex nut Tighten finger...

Page 120: ...ut securing the hub 4 Remove the brake caliper KC283 5 Remove the hub assembly 6 Remove the four cap screws securing the brake disc CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all hub components 2 Inspect all threads for stripping or damage 3 Inspect the brake disc for cracks or warping 4 Inspect the hub for pits c...

Page 121: ...ve the wheel 2 Drain the brake fluid from the caliper hose and master cylinder 3 Remove the brake hose from the caliper then remove the caliper and plug the brake fluid port 4 Compress the caliper holder against the caliper and remove the outer brake pad then remove the inner brake pad PR237 PR238 5 Remove the caliper holder from the caliper and account for the brake caliper O ring Do not remove t...

Page 122: ...r and install the inner brake pad then install the outer pad PR238 PR239 3 Place the brake caliper assembly into position and secure with the cap screws Tighten the caliper to 20 ft lb 4 Place a new crush washer on each side of the brake hose fitting and install it on the caliper Tighten to 20 ft lb 5 Fill the reservoir then bleed the brake system see Section 2 6 Install the wheel Tighten to 40 ft...

Page 123: ...ions 7 Replace gear s 8 Replace axle 9 Replace axle Problem Braking poor Condition Remedy 1 Pad worn 2 Pedal free play excessive 3 Brake fluid leaking 4 Hydraulic system spongy 5 Master cylinder brake cylinder seal worn 1 Replace pads 2 Replace pads 3 Repair replace hydraulic system component s 4 Bleed hydraulic system correct or repair leaks 5 Replace master cylinder Problem Brake lever travel ex...

Page 124: ... TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 2 Rear A Arms 7 3 Wheels and Tires 7 4 Troubleshooting 7 6 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 125: ...e the ATV on a support stand to elevate the front wheels then remove the wheels 2 Remove the cotter pin from the nut Discard the cotter pin 3 Remove the nut securing the hub 4 Remove the brake caliper Account for two cap screws KC187A 5 Remove the hub assembly 6 Remove the cap screws securing the ball joints to the knuckle KC313A 7 Tap the ball joints out of the knuckle then free the knuckle from ...

Page 126: ...le assembly onto the ball joints and secure with cap screws Tighten to 35 ft lb 6 Apply grease to the hub and drive axle splines then install the hub assembly onto the drive axle 7 Secure the hub assembly with the nut Tighten only until snug 8 Secure the brake caliper to the knuckle with the two patch lock cap screws Tighten to 20 ft lb 9 Secure the hub nut from step 7 to the shaft axle Tighten to...

Page 127: ... Secure the brake caliper to the knuckle with the two cap screws right side only Tighten the cali per to 20 ft lb 7 Compress the hand brake lever and engage the brake lever lock then secure the hub nut from step 5 to the drive axle Tighten to 200 ft lb 8 Install a new cotter pin and spread the pin to secure the nut 9 Secure the shock absorber to the frame with a cap screw and new lock nut Tighten ...

Page 128: ...ge wear or punctures NOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Be sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe in and toe out and adjust as necessary see Section 8 4 Test drive the ATV on a dry level surface and note any pulling to the left or right...

Page 129: ...oose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Rear wheel oscillation Condition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Auxiliary brake adjusted incorrectly 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 1 Replace bearing...

Page 130: ...ebar Grip 8 3 Steering Knuckles 8 4 Measuring Adjusting Toe In 8 5 Front Rack 8 6 Front Bumper Assembly 8 6 Front Body Panel Fender 8 7 Exhaust System 8 8 Rear Body Panel Rack 8 9 Troubleshooting 8 11 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 131: ...me 5 Remove the cap screw securing the lower steering post to the bearing Account for a flat washer KC184B 6 Remove the steering post from the ATV CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Wash the tie rod ends in parts cleaning solvent Dry with compressed air Inspect the pivot area for wear Apply a low temperature gre...

Page 132: ... the lower steering post arm and tighten to 30 ft lb then install new cotter pins KC184A 4 Place the handlebar and caps in place on the steer ing post and with the handlebar correctly posi tioned tighten the cap screws to 20 ft lb KC0058 5 Install the steering post cover then install the front body panel fender see Front Body Panel Fender in this section Handlebar Grip REMOVING 1 Loosen but do not...

Page 133: ...rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then remove the knuckle 9 Remove the snap ring from the knuckle then remove the bearing PR287A PR288 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all knuckle components 2 Inspect t...

Page 134: ...usting Toe In 1 Thoroughly wash the ATV to remove excess weight mud etc 2 Refer to the specifications and ensure the tires are properly inflated to the recommended pressure NOTE Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur 3 Place the ATV in a level position taking care not to push down or lift up on the front end then turn the handlebar to the straigh...

Page 135: ...racking or bending 3 Inspect threaded areas of all mounting bosses for stripping 4 Inspect for missing decals and or reflectors INSTALLING 1 Place the rack into position on the frame and front fender panel Install the cap screws and lock nuts and finger tighten only 2 Install the two cap screws and lock nuts securing the rack to the fenders Tighten all hardware securely Front Bumper Assembly REMOV...

Page 136: ...ws A then remove the rein stallable rivets B and remove the tank cover KC219A KC220 4 Remove the shift knob then remove the shift mechanism splash shield KC211 5 Remove the screws securing the front body to the front body supports then remove the left side and right side footwell fasteners KC204A 6 Remove the electric panel then disconnect the LCD gauge connector ignition switch and acces sory out...

Page 137: ...nt body to the front body supports then install the left side and right side footwell fasteners Do not tighten at this time 4 Place the gas tank cover into position and secure with the existing hardware then install the two cap screws securing the rear of the panel to the frame Tighten all cap screws and fasteners securely at this time 5 Install the electric panel side panels and seat Exhaust Syst...

Page 138: ...e side frame and the cap screws securing the rear fenders to the footwells KC317A KC316 2 Disconnect the battery negative cable first and remove from the battery compartment then dis connect the starter relay wires and route the wiring out of the compartment KC322A 3 Remove the auxiliary brake reservoir from the body but do not disconnect the hose then route and secure the hose and reservoir out o...

Page 139: ... panel fender in place on the ATV then secure with the cap screws on the side frame and the rear rack assembly Tighten all fas teners securely KC317A KC320A 2 Connect the light connectors and secure to the frame then install the battery starter relay and auxiliary brake Connect all wiring making sure to connect the positive cables first KC279 KC322 3 Secure the rear fenders to the footwells and ti...

Page 140: ...n tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Tire wear rapid or uneve...

Page 141: ...ONTROLS INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 2 LCD Gauge 9 3 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 142: ...ion of the pivot hole 3 Inspect the reservoir for cracks and leakage 4 Inspect the banjo fitting and bolt for cracks and deterioration and the condition of the fittings threaded and compression INSTALLING 1 Position the brake housing on the handlebar Secure with clamp screws then tighten securely 2 Using two new crush washers connect the banjo fitting to the master cylinder then secure with the ba...

Page 143: ...ine screws ADJUSTING To adjust throttle cable free play see Section 2 LCD Gauge REPLACING To replace the LCD gauge use the following proce dure 1 Remove the electric panel and disconnect the LCD gauge connector then remove three mounting screws two in front and one in back of gauge and remove the gauge KC210G KC323A 2 Install the new gauge and secure with the mount ing screws then connect the gaug...

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