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Arctic Cat 2009 366, Service Manual

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Arctic Cat 2009 366 Service Manual Download Page 107

6-10

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 existing cap

screws. Tighten to 23 ft-lb.

„

NOTE: If a new gear housing is being installed,

tighten the cap screws to 28 ft-lb.

CD103

CD110

8. Install the proper shim onto the ring gear spider

assembly making sure the chamfer side of the

shim is facing toward the ring gear. Install the ring

gear in the housing; then install the outside shim

with the chamfer side of the shim toward the ring

gear.

„

NOTE: The spider and ring gear assembly must

be replaced as a complete unit.

CC896

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Summary of Contents for 2009 366

Page 1: ......

Page 2: ...anual Manual Service Service TABLE OF CONTENTS Foreword Click on the red text to go 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 ...

Page 3: ...TENTS General Specifications 1 2 Torque Specifications 1 2 Torque Conversions ft lb N m 1 3 Tightening Torque General Bolts 1 3 Break In Procedure 1 3 Gasoline Oil Lubricant 1 3 Genuine Parts 1 4 Preparation For Storage 1 4 Preparation After Storage 1 5 Back to TOC ...

Page 4: ...PONENTS Rear Part Part Bolted To Torque ft lb N m A Arm Frame 35 47 Knuckle Ball Joint 35 47 Shock Absorber Frame 35 47 Shock Absorber Upper A Arm 35 47 Knuckle A Arm 35 47 SUSPENSION COMPONENTS Rear Shock Absorber Upper Frame 35 47 Shock Absorber Lower Lower A Arm 35 47 A Arm Frame 35 47 Knuckle A Arm 35 47 ENGINE TRANSMISSION Clutch Shoe Crankshaft 147 199 Clutch Cover Housing Assembly Crankcase...

Page 5: ...Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated 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 ...

Page 6: ...Manual for the correct part number quan tity and description Preparation For Storage Arctic Cat recommends the following procedure to prepare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV to dry thoroughly DO NOT get water into any part...

Page 7: ...sure many miles and hours of trouble free riding Arctic Cat recommends the following proce dure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the muf fler 3 Check all control cables for signs of wear or fray ing Replace if necessary 4 Change the engine transmission oil and filter 5 Charge the battery then install Connect the bat tery cables 6 Check the enti...

Page 8: ...Plug 2 7 Muffler Spark Arrester 2 8 Adjusting Throttle Cable 2 8 Adjusting Engine RPM Idle 2 9 Engine Transmission Oil Filter Strainer 2 9 Front Differential Rear Drive Lubricant 2 10 Tires 2 11 Steering Components 2 11 Driveshaft Coupling 2 11 Suspension Shock Absorbers Bushings 2 11 Nuts Bolts Cap Screws 2 12 Ignition Timing 2 12 Lights 2 12 Shift Lever 2 14 Frame Welds Racks 2 15 Electrical Con...

Page 9: ...Spark Plug I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R Carburetor Float Chamber D Engine Idle RPM I I A Engine Transmission Oil Level I A Engine Transmission Oil Filter R R R R 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 boot...

Page 10: ...nt hose 3 Remove the battery from 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...

Page 11: ...dule 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 it CLEA...

Page 12: ...he open end of the element KC143 6 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the carburetor 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 KC123 CAUTION A torn air filter ele...

Page 13: ...hten 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 tappet clearance use the following procedure NOTE The seat left si...

Page 14: ...ttach the high ten sion lead to the plug and ground the plug on the cylinder head well away from the spark plug hole 4 Attach the Compression Tester Kit NOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the throttle lever in the full open position crank the engine over with the electric starter until the gauge shows a peak reading of 95 115 psi five t...

Page 15: ...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 3 Install the spark arrester assembly with gasket then secure with the cap screws Tighten to 48 in lb KC145 Adjusting Throttle Cable To adjust the throttle cable free play follow this proce dure 1 Slide the rubber boot away then loosen the jam nut from the...

Page 16: ...on case and allow the filter to drain completely Install the plug and tighten securely 6 Using the adjustable Oil Filter Wrench and a suit able wrench remove the old oil filter NOTE Clean up any excess oil after removing the filter 7 Apply oil to a new filter seal ring and check to make sure it is positioned correctly then install the new oil filter Tighten securely 8 Install the engine drain plug...

Page 17: ...o position beneath the crankcase and secure with the cap screws Tighten securely 5 Place the strainer cap into position on the strainer making sure the O ring is properly installed then secure with the cap screws Tighten securely CC091D 6 Install the belly panel Front Differential Rear Drive Lubricant When changing the lubricant use approved SAE 80W 90 hypoid gear lube To check lubricant remove th...

Page 18: ...cally to ensure safe and proper operation A Handlebar grips not worn broken or loose B Handlebar not bent cracked and has equal and complete full left and full right capability C Steering post bearing assembly bearing housing not broken worn or binding D Ball joints not worn cracked or damaged E Tie rods not bent or cracked F Knuckles not worn cracked or damaged G Cotter pins not damaged or missin...

Page 19: ...or may be damaged the key may be sheared the trigger coil bracket may be bent or damaged or the CDI unit may be faulty Lights Rotate the ignition switch to the lights position the headlights and taillights should illuminate Test the brakelights by compressing the brake lever The brake lights should illuminate HEADLIGHTS NOTE The bulb portion of a headlight is fragile HANDLE WITH CARE When replacin...

Page 20: ...he head lights and the back up lights are outboard of the tail lights brakelights To replace the bulbs use the following procedure 1 Rotate the bulb socket counterclockwise to release from light housing then press in on the bulb and turn counterclockwise to release from the socket KC158A 2 Install a new bulb and press in rotating clockwise to secure then place the socket into the light hous ing an...

Page 21: ...ged turn the ignition switch to the ON position then shift the transmission into each of the gear positions and note that the gear position indicated on the LCD cor responds to the gear position selected by the lever If the indicator does not correspond to the selected gear it will be necessary to test drive the ATV to deter mine if the gear shift position switch is faulty or the shift lever needs...

Page 22: ...dure 1 With the master cylinder in a level position check the fluid level in the reservoir On the hand brake if the level in the reservoir is adequate the sight glass will appear dark If the level is low the sight glass will appear clear On the auxiliary brake the level must be between the MIN and MAX lines on the reservoir 738 420A AL681 2 Compress the brake lever pedal several times to check for...

Page 23: ...ired is replacement of the brake pads when they show excessive wear Check the thickness of each of the brake pads as follows 1 Remove a front wheel 2 Measure the thickness of each brake pad 3 If thickness of either brake pad is less than 1 0 mm 0 039 in the brake pads must be replaced PR376B NOTE The brake pads should be replaced as a set 4 To replace the brake pads use the following proce dure A ...

Page 24: ...at and right side engine cover then remove the cap screw securing the auxiliary brake pedal to the frame Account for a flat washer KC149A 2 Slide the auxiliary brake pedal part way off the pivot stud but do not remove then remove the cap screws from the V belt housing and remove the cover Account for two alignment pins and a gas ket KC142A 3 Remove the nut securing the movable drive face to the cl...

Page 25: ...ce the V belt onto the driven pulley making sure the arrows point in the direction of rotation then pinch the belt together in front of the driven pulley and place it over the clutch shaft KC135 KC131 2 Install the bushing over the clutch shaft then install the movable drive face assembly on the clutch shaft KC128 KC138 3 With two drops of red Loctite 271 on the threads and with the splines of the...

Page 26: ...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 KC153A 6 Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder then secure with the flat washer and cap screw and tighten to 20 ft lb KC149A Back to TOC Back to Section TOC Back ...

Page 27: ...3 1 3 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 366 Table of Contents 3 6 Back to TOC ...

Page 28: ...n max wobble method 0 35 mm Valve Guide Inside Diameter 5 000 5 015 mm Valve Stem Outside Diameter intake exhaust 4 975 4 990 mm 4 955 4 970 mm Valve Stem Runout max 0 05 mm Valve Head Thickness intake exhaust 2 03 mm 2 28 mm Valve Face Seat Width min intake exhaust 2 25 mm 2 55 mm Valve Seat Angle intake exhaust 45 Valve Face Radial Runout max 0 03 mm Valve Spring Free Length min 42 8 mm Valve Sp...

Page 29: ...el 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 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Eng...

Page 30: ...tion coil defective 9 Float out of adjustment 10 Jets obstructed 11 Pilot screw setting improper 12 Fuel injector obstructed 1 Adjust clearance 2 Replace service seats valves 3 Replace cylinder head 4 Replace arms shafts 5 Replace magneto 6 Replace CDI unit 7 Adjust gap replace plug 8 Replace ignition coil 9 Adjust float height 10 Clean jets 11 Adjust pilot screw 12 Replace fuel injector Problem E...

Page 31: ...er 5 Repair seats 6 Clean replace plug 7 Replace arms shafts 8 Adjust gap replace plug 9 Clean jets 10 Adjust float height 11 Clean element 12 Drain excess oil change oil 13 Tighten replace manifold 14 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 2 Oil low 3 Octane low gasoline poor 4 Oil pump defective 5 Oil circuit obstructed 6 Gasoline leve...

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

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

Page 34: ...NOTE The engine transmission does not have to 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 nut...

Page 35: ...it Note the loca tion of the two alignment pins 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 camsh...

Page 36: ...oner by lifting it from the chain cavity then 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...

Page 37: ...te side circlip prior to using the puller MD1219 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 sequ...

Page 38: ...ed 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 ...

Page 39: ... Using 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...

Page 40: ...specifications Measuring Rocker Arm Shaft Outside Diameter 1 Using a micrometer measure the outside diameter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifications Installing Valves 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 lo...

Page 41: ...s 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 cylinder 2 Using a feeler gauge measure each pist...

Page 42: ...the top position MD1343A CYLINDER CYLINDER HEAD ASSEMBLY NOTE If the cylinder cylinder head assembly cannot be trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chamber being careful not to nick scrape or damage the combustion chamber or the sealing surface 2 Inspect the spark plug hole for any dam...

Page 43: ...s tears breaks or chips 2 If the chain guide is damaged it must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90 from the first measurements for a total of six measurements The trueness out of roundness is the difference between the highest and lowest re...

Page 44: ...g journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Loosen the jam nuts and adjuster screws CC005D 2 Place a strip of plasti gauge in each of the cam shaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve co...

Page 45: ...0A 2 If damaged the camshaft must be replaced Installing Top Side Components A Piston B Cylinder 1 Lubricate the piston pin connecting rod and piston pin bore with motor oil then 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 downwards NOTE The piston should be installed so the arrow points towards the exh...

Page 46: ...n the preceding sub section must precede this procedure 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder MD1349 6 Place a new 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 CAUTION The cylinder s...

Page 47: ... place the camshaft in position and verify that the timing mark on the magneto is visible through the inspection plug and that the timing marks on 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 camshaf...

Page 48: ...reads coated with red Loctite 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 Rem...

Page 49: ...l the remaining cap screws Tighten only until 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 securely then install t...

Page 50: ...6 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 in the preceding sub section must precede this procedure 4 Remove the rotor flywheel nut MD1194 5 Install the...

Page 51: ...opper spring tension MD1239 9 Remove the shift detent cam 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 crankshaft bear ing retainer Remov...

Page 52: ...er idler gear No 2 and starter idler gear 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...

Page 53: ...ap screws securing the V belt cover to the clutch 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 driv...

Page 54: ...e the cap screws holding the clutch cover onto 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...

Page 55: ...the direction of the green dot or the word OUTSIDE 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 S...

Page 56: ...his procedure 20 Remove three Phillips head screws holding the oil pump and remove the oil pump Account for two alignment pins MD1060 21 Remove the four cap screws securing the oil strainer cap then remove the Phillips head screws securing the oil strainer Account for the O ring MD1207 AT THIS POINT To service clutch components see Servicing Right Side Components sub section AT THIS POINT To servi...

Page 57: ...utch shoe assembly with the green dot or the word OUT SIDE directed away from the clutch shoe KC330 2 Place the clutch housing onto the clutch shoe one way clutch NOTE It will be necessary to rotate the clutch housing counterclockwise to properly seat the one way clutch KC331A 3 Check that the clutch shoe can only be rotated counterclockwise in respect to the clutch housing If the clutch shoe lock...

Page 58: ...lace two alignment pins and the oil pump into position on the crankcase and secure with the Phil lips head screws coated with blue Loctite 243 Tighten to 8 ft lb MD1060 4 Place the thrust washer and drive pin into position on the oil pump shaft install the oil pump driven gear making sure the recessed side of the gear is directed inward and secure with a new snap ring NOTE Always use a new snap ri...

Page 59: ...case MD1286 9 Install gear shift position switch spacer and switch making sure to align the drive pin with the slot in the shift shaft KC325A KC326B B Clutch Cover C Fixed Drive Face D Movable Drive Face NOTE Steps 1 9 in the preceding sub section must precede this procedure 10 Install two alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 11 Tighten the...

Page 60: ...ver cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V belt to drop into the pulley approxi mately 3 4 in KC137 NOTE The arrows on the V belt should point in direction of engine rotation 16 Making sure the movable drive face rollers are in position pinch the V belt together near its center and slide the spacer and movable drive face onto the shaft ...

Page 61: ...procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the left side and right side cap screws securing the crankcase halves noting the position of the different sized cap screws for joining purposes MD1...

Page 62: ... reverse idler gear spacer and sleeve Account for the washer MD1325 3 Remove the driveshaft MD1326 4 Remove the shift fork shaft and the outer shift fork MD1327 5 Remove snap ring and gear from the output side of the gear cluster Remove the gear cluster and the inner shift fork together Account for snap ring gear and washer MD1328 6 Noting the position of the slot on the end remove the shift cam a...

Page 63: ...t of the secondary transmission output shaft 2 Install the secondary driven output shaft assembly onto the crankcase 3 Mount the indicator tip of the dial indicator on the secondary driven bevel gear centered on the gear tooth 4 While rocking the driven bevel gear back and forth note the maximum backlash reading on the gauge 5 Acceptable backlash range is 0 05 0 33 mm 0 002 0 013 in Correcting Bac...

Page 64: ...tern 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...

Page 65: ... exceed specifications NOTE Proceed to check runout on the other end of the crankshaft by positioning the indicator con tact at point 2 and following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the outside edge of one web to the outside edge of the other web ATV 1017 2 Acceptable width range must be within specifications COUNTERSHAFT Disassembling 1 Remov...

Page 66: ...ents on the right side crankcase half NOTE If the output shaft was removed make sure that the proper shim is installed 1 Install the output shaft into the crankcase making sure the two gears shim washer and nut are in the correct order MD1199 MD1079 2 Apply red Loctite 271 to the threads of the output shaft Install and tighten the nut 59 ft lb Using a punch peen the nut MD1333 3 Apply a liberal am...

Page 67: ...place install the washer gear and snap ring MD1032 MD1198 8 Install the outer shift fork and the 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 driven gear NOTE Align the bearing alignmen...

Page 68: ...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 Installing Engine Tran...

Page 69: ...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 KC238 Back to TOC Back to Section TOC Next Back ...

Page 70: ...ncer duct and intake housing to carburetor 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 ...

Page 71: ... install the gas tank see Section 4 13 Install the front body panel front rack and foot wells see Section 8 14 Pour the appropriate quantity and grade oil into the crankcase then connect the negative battery cable 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 o...

Page 72: ... Fuel Lubrication Cooling 4 2 Carburetor Specifications 4 2 Electric Choke 4 2 Carburetor 4 3 Throttle Cable Free Play 4 8 Engine RPM Idle 4 8 Gas Tank 4 9 Oil Filter Oil Pump 4 10 Testing Oil Pump Pressure 4 10 Oil Cooler 4 11 Troubleshooting 4 12 Back to TOC ...

Page 73: ...ove the choke assembly from the carburetor taking care not to force the plunger from the carburetor body INSPECTING TESTING 1 Inspect the plunger A for scoring or scratches the needle B for damage to the tip the spring C for breakage and the O ring D for breaks KC328A 2 With the choke at room temperature approxi mately 70 F measure plunger extension Mea surement A should be 18 6 19 1 mm KC328B 3 C...

Page 74: ...en disconnect the electric choke connector and vent hose KC256A KC263 KC264A WARNING Whenever any maintenance or inspection is per formed on the fuel system during which there may be fuel leakage there should be no welding smoking open flames etc in the area KEY 1 Cover 2 Screw 3 Spring 4 Vacuum Piston 5 Spring Seat 6 Jet Needle 7 Needle Jet 8 Jet Holder 9 Main Jet 10 Slow Jet 11 Starter Jet 12 Fl...

Page 75: ...uum 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 CC748 4 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring KC0022A KC0063A 5 Remove the float pin KC0024A 6 Lift the f...

Page 76: ... Rinse thoroughly 4 Dry all components with compressed air only making sure all holes orifices and channels are unobstructed 5 Inspect the carburetor body for cracks nicks stripped threads and any imperfections in the cast ing 6 Inspect the vacuum piston diaphragm for cracks imperfections in the casting or cracks and tears in the rubber 7 Inspect float for damage 8 Inspect gasket and O rings for d...

Page 77: ...en turn it counterclockwise the recommended number of turns as an initial set ting NOTE Note the locations of the jets and holder during assembling procedures CC761A 3 Install the starter jet and slow jet Tighten securely KC0032A 4 Install the main jet into the needle jet holder and tighten securely then install the needle jet and needle jet holder assembly into the carburetor and tighten securely...

Page 78: ...assembly with the pump housing and three screws Tighten securely CC748 8 Place the jet needle spring seat and spring into the vacuum piston then place the assembly down into the carburetor CC746 9 Place the top cover into position then secure with the Phillips head screws Tighten securely KC0019A INSTALLING 1 Connect the vent hose to the carburetor then con nect the electronic choke connector and ...

Page 79: ...ment lug on the carburetor is between the two tabs on the air intake pipe then tighten the clamp securely KC245A KC256A 4 Connect the intake air housing and tighten all clamps and mounting hardware securely KC257 5 Install the gas tank see Gas Tank in this section Throttle Cable Free Play To adjust throttle cable free play see Section 2 Engine RPM Idle To adjust the idle RPM see Section 2 Back to ...

Page 80: ...move the clamp securing the gasline hose and remove the hose from the gas tank valve KC241A 6 Using a suitable block hold the front body open and remove the gas 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 ...

Page 81: ...rame with the cap screws A and tighten securely then install the gas tank cover and secure with the rein stallable rivets B 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 pum...

Page 82: ...l pressure is higher than specified check for clogged oil passage clogged oil filter or improper installation of the oil filter Oil Cooler 0743 004 REMOVING NOTE It is not 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 CAUTION Elevate and secu...

Page 83: ...orrect 4 Float height incorrect 5 TPS out of adjustment 1 Clean tighten jet 2 Clean outlet 3 Adjust screw 4 Adjust float height 5 Adjust TPS Problem Medium or high speed 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 R...

Page 84: ...bution Module 5 4 Fuses 5 5 Ignition Coil 5 5 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 10 Neutral Start Front Drive Actuator Start in Gear 2WD Relays 5 11 Headlights 5 11 Taillights Brake...

Page 85: ...ulb s are good that the connections are clean and tight that the battery is fully charged and that all appropriate switches are activated 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 select...

Page 86: ...perature 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 thermometer 733 554C 3 On ...

Page 87: ...hen 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 any type of electrical system failure always check the fuses first KC210A NOTE The ignition switch must be in the LIGHTS position 1 Remove all fuses from the distribution...

Page 88: ... does not show as specified replace ignition coil Spark Plug Cap 1 Connect the red tester lead to one end of the cap then connect the black tester lead to the other end of the cap AR603D 2 The meter reading must be within specification NOTE If the meter does not read as specified replace the spark plug cap PEAK VOLTAGE NOTE All of the peak voltage tests should be made using the Fluke Model 73 Mult...

Page 89: ...e 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 with the cap screw threads coated with blue Loctite 242 Tighten securely CD071 Ignition Switch The ignition switch harness connects to the switch with a three pin connector To access the connector remove the access...

Page 90: ...ance 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 show an open circuit 4 With the switch in the RUN position the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resi...

Page 91: ...the brown lavender wire in the supply harness 3 Turn the ignition switch to the ON position The meter must show 12 DC volts 4 Connect the red tester lead to the white blue wire in the supply harness The meter must show 12 DC volts 5 Select the 4WD position on the front drive selector switch then connect the red tester lead to the white blue wire in the supply harness The meter must show 0 DC volts...

Page 92: ... the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter If any other type of tester is used readings may vary due to internal circuitry NOTE The battery must be at full charge for this test Trigger Coil 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the green wire then connect the black tester lead to the blue wire 3 Crank the engine over using the el...

Page 93: ...all amount of grease to the O ring seal on the starter then install the starter into the crank case Secure with two cap screws making sure the engine ground is secured by the rear cap screws Tighten to 8 ft lb KC201A 2 Secure the positive cable to the starter with the nut Tighten to 8 ft lb 3 Connect the battery CDI Unit The CDI is located on the electrical tray in front of the steering post NOTE ...

Page 94: ...ion switch must be in the LIGHTS position 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire then connect the red tester lead to the white wire 3 With the dimmer switch in the LO position the meter must show battery voltage 4 Remove the red tester lead from the white wire and connect to the lavender wire 5 With the dimmer switch in the HI position...

Page 95: ...ar frame supports attached by a metal tab They may be released from the frame by depressing the release with a small screwdriver KC279 KC280 VOLTAGE 1 Release the wire connectors from the frame then disconnect the connectors NOTE Perform this test on the main harness side of the connectors 2 Connect the black tester lead to the brown laven der wire then connect the red tester lead to the lavender ...

Page 96: ...es not charge Condition Remedy 1 Lead wires connections shorted loose open 2 Magneto coils shorted grounded open 3 Regulator rectifier defective 1 Repair replace tighten lead wires 2 Replace magneto coils 3 Replace regulator rectifier Problem Magneto charges but charging rate is below the specification Condition Remedy 1 Lead wires shorted open loose at terminals 2 Stator coils magneto grounded op...

Page 97: ...y 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 too rapidly Condition Remedy 1 Electrolyte contaminated 2 Specific gravity too low 3 Charging system not charging 4 Cell plates overcharged damaged 5 Battery short circuited 6 Spe...

Page 98: ...LE OF CONTENTS Drive System 6 2 Front Drive Actuator 6 2 Front Differential 6 3 Drive Axles 6 14 Rear Gear Case 6 18 Hub 6 19 Hydraulic Brake Caliper 6 19 Troubleshooting Drive System 6 21 Troubleshooting Brake System 6 22 Back to TOC ...

Page 99: ...h 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 runs constantly or makes squealing or grinding sounds the actuator must be replaced ...

Page 100: ...s 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 harness to the frame with a nylon cable tie Front Differential REMOVING DIFFERENTIAL 1 Secure th...

Page 101: ...ow 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 KC291A Disassembling Input Shaft NOTE This procedure can be performed on a rear gear case however some components may vary from model to model The technician should use discre...

Page 102: ...mponents 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 securing the input shaft bearing then place the pinion housing in...

Page 103: ...TE 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 KX222 4 Install the input shaft into the housing then install the front boot and secure with an appropriate boot clamp and the rear boot with an appropriate boot clamp CD112 5 Using a new O ring lubricated with grease install the front driv...

Page 104: ...ake 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 If the cover is difficult to remove pry on the cover in more than one recessed location 4 Remove the left gear case bearing flange assembly and account for a shim Mark the shim as left side KX177 KX178 5 Place the differential with the open ...

Page 105: ...rs are scribed onto the gears the ring gear has the number on the oppo site side of the gears and the pinion gear has the number on the end of the pinion gear shaft by the splines If no number is present it should be con sidered as being in the 0 category NOTE If the gear case housing is being replaced proceed to the following Shimming Proce dure Shim Selection sub section Shimming Procedure Shim ...

Page 106: ... assembly with SAE 80W 90 hypoid gear lubricant prior to pressing assembly into gear case housing Assembling Pinion Gear 1 Install the bearing onto the pinion shaft Install the pinion shaft collar CC882 CC883 2 Place the pinion assembly in a bearing puller then install the bearing using a press CC884 3 Install the pinion gear assembly into the housing Using the 48 mm Internal Hex Socket secure the...

Page 107: ... housing then secure with the existing cap screws Tighten to 23 ft lb NOTE If a new gear housing is being installed tighten the cap screws to 28 ft lb CD103 CD110 8 Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear Install the ring gear in the housing then install the outside shim with the chamfer side of the shim tow...

Page 108: ...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 unless the bearing is clearly damaged NOTE This procedure can be performed on a rear gear case 1 Place a 1 4 in drill bit on the inside surface of the needle bearing against the bottom side then drill through the pinion shaft needle...

Page 109: ...90 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 case 1 Remove the seal using a seal removal tool CC899 2 Using a press remove the bearing CC900 3 Using a pres...

Page 110: ...th 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 AF610D AF897D 4 Install the brake calipers and secure with the patch lock cap screws tightened to 20 ft...

Page 111: ... 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 stationary pull the top of the knuckle out and down until it is free of the drive axle KC285 9 Place a drain pan under the ATV t...

Page 112: ...s 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 the shaft Note the direction of the bearing for assembling purposes CD023 4 Note the difference inside each bearing ring end for assembling purposes then remove the bearing ring NOTE The recess of the bearing must face toward the housing CD022 5 I...

Page 113: ...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 sized clamps from removal NOTE The boot is positioned correctly when the small end of the boot seats down into the recessed groove CD754 10 Using the CV Boot Clamp Tool secure both out side boot clamps CD024 ASSEMBLING AXLES 1 Install the inner boot wi...

Page 114: ...ousing 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 properly CD021 7 Slide the boot over the housing then using the boot clamp pliers secure the boot with the clamp CD024 8 Inspect the axle components for correct position ing of the four clamp...

Page 115: ...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 tight at this time 3 Install the brake caliper on the steering knuckle Tighten to 20 ft lb then pump up the hand brake lever and engage the brake lever lock 4 Tighten the hub hex nut from step 2 to 200 ...

Page 116: ...cessary 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 cracks loose studs or spline wear INSTALLING 1 Secure the brake disc to the hub with the four cap screws coated with blue Loctite 243 Tighten to 15 ft lb 2 Apply grease to the splines in the hub 3 Install the hub assembly onto the shaft 4 Secure...

Page 117: ...a suitable plug to prevent contamination during cleaning PR240A CLEANING AND INSPECTING 1 Clean all caliper components except the brake pads with parts cleaning solvent 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Section 2 ASSEMBLING INSTALLING 1 Install the caliper onto the caliper holder making sure the caliper is correctly oriented on the holder PR23...

Page 118: ...ndition Remedy 1 Rear axle shafts serration worn broken 1 Replace shaft Problem Power not transmitted from engine to either front wheel Condition Remedy 1 Secondary drive driven gear teeth 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 damaged 7 Slidi...

Page 119: ... or repair leaks 5 Replace master cylinder Problem Brake lever travel excessive Condition Remedy 1 Hydraulic system entrapped air 2 Brake fluid low 3 Brake fluid incorrect 4 Piston seal cup worn 1 Bleed hydraulic system 2 Add fluid to proper level 3 Drain system replace with correct fluid 4 Replace master cylinder Problem Brake fluid leaking Condition Remedy 1 Connection joints loose 2 Hose cracke...

Page 120: ...7 1 7 SECTION 7 SUSPENSION 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 ...

Page 121: ...e support stand Front A Arms REMOVING 1 Secure 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 o...

Page 122: ... Install the knuckle 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 sha...

Page 123: ...ive 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 to 35 ft lb 10 Secure the shock absorber to the lower A arm with a cap screw and new lock nut Tighten to 20 ft lb 11 Secure the boot guard to the lower A arm with the two cap screws Tighten securely 12 Install the wheel and...

Page 124: ...he 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 during acceleration deceleration and braking NOTE If pulling is noted measure the circumfer ence of the front...

Page 125: ...ition Remedy 1 Cap screws suspension system loose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Rear wheel oscillation Condition Remedy 1 Rear 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 Re...

Page 126: ...ng Frame 8 2 Steering Post Tie Rods 8 2 Handlebar 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 ...

Page 127: ...les at this time 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 t...

Page 128: ... rod ends into 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 Loo...

Page 129: ...e caliper 5 Remove the hub assembly 6 Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out 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 excessive...

Page 130: ...the ATV from the support stand Measuring Adjusting 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 fron...

Page 131: ...g a pressure washer 2 Inspect all welds for cracking 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 ...

Page 132: ...ed from the frame KC223 3 Remove the cap screws 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...

Page 133: ...ody 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 System REMOVING MUFFLER 1 ...

Page 134: ...ap 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 of the way making sure ...

Page 135: ...ssing decals INSTALLING 1 Place the rear body 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 Se...

Page 136: ...cap screws 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires 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 sh...

Page 137: ...9 1 9 SECTION 9 CONTROLS INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 2 LCD Gauge 9 3 Back to TOC ...

Page 138: ...r wear 2 Inspect the brake lever for elongation 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...

Page 139: ...o the handlebar and secure with the two machine 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 wit...

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