Arctic Cat 2011 700 Diesel SD Service Manual Download | Manualshive

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139

PR239C

5. Making sure brake fluid does not contact the brake

pads, compress the caliper holder toward the cali-

per and install the inner brake pad; then install the

outer pad.

PR238

PR239

6. Place the brake caliper assembly into position and

secure with new “patch-lock” cap screws. Tighten

the caliper to 20 ft-lb.

7. Place a new crush washer on each side of the brake

hose fitting and install it on the caliper. Tighten to

20 ft-lb.

8. Fill the reservoir; then bleed the brake system (see

Periodic Maintenance/Tune-Up).

9. Install the wheel. Tighten to 45 ft-lb.

10. Remove the ATV from the support stand and ver-

ify brake operation.

CAUTION

If brake pads become contaminated with brake fluid,
they must be thoroughly cleaned with brake cleaning
solvent or replaced with new pads. Failure to do so
will result in reduced braking and premature brake
pad failure.

! WARNING

Never use brake fluid from an open container or reuse
brake fluid. Moisture-contaminated brake fluid could
cause vapor build-up (expansion) during hard braking
resulting in greatly increased stopping distance or
loss of control leading to injury or death.

Manual

Table of Contents

For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

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Summary of Contents for 2011 700 Diesel SD

Page 1: ...he possibility of severe personal injury or even death A CAUTION identifies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE identifies supplementary information worthy of particular atten tion The symbol AT THIS POINT directs the technician to certain and specific procedures to p...

Page 2: ...em 104 Battery 104 Testing Electrical Components 105 Switches 105 Accessory Receptacle Connector 105 Brakelight Switch Auxiliary 105 Brakelight Switch Handlebar Control 106 Cooling Fan Switch 106 Engine Coolant Temperature ECT Switch Thermistor 107 Glow Plug Controller Relay 107 Fan Motor 108 Fuse Block Power Distribution Module 108 Electronic Speedometer Speed Sensor 109 Ignition Switch 110 Handl...

Page 3: ...PONENTS Exhaust Pipe Exhaust Manifold 14 19 Spark Arrester Muffler 48 in lb 5 ELECTRICAL COMPONENTS Ground Wire Transmission 8 11 CHASSIS COMPONENTS Shift Lever Shift Axle 8 11 DRIVE TRAIN COMPONENTS Part Part Bolted To Torque ft lb N m Front Mounting Bracket Engine 20 27 Engine Mount Upper Frame 35 48 Engine Mount Front Rear Frame 20 27 Front Differential Frame Differential Bracket 38 52 Rear Dri...

Page 4: ...t Shaft Output Shaft Coupler 20 27 Output Shaft Nut Output Shaft 80 108 Starter V Belt Housing 35 48 Flywheel PTO Shaft Crankshaft 40 54 Crankshaft Pulley Timing Belt Drive Pulley 9 12 Chamber Ring Nut Chamber Step 1 Step 2 72 130 98 177 Glow Plug Cylinder Head 18 24 Crankshaft Pulley Crankshaft 260 354 Timing Belt Idler Nut Engine Block 29 39 V Belt Cover V Belt Housing 9 12 V Belt Housing Crankc...

Page 5: ...FFERENTIAL REAR DRIVE LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W 90 hypoid This lubricant meets all of the lubrica tion requirements of the Arctic Cat ATV front differen tials and rear drives FILLING FUEL TANK ATV0049B Since fuel expands as its temperature rises the fuel tank must be filled to its rated capacity only Expan sion ...

Page 6: ...tore in a clean dry area 9 Store the ATV indoors in a level position Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free rid ing Arctic Cat recommends the following procedure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the muf fler 3 Check all control wires and cables for sign...

Page 7: ...s I A Throttle Cable I C L A R Engine Oil Level I Engine Oil Filter Replace after initial 300 miles R R Front Differential Rear Drive Lubricant I R 4 Yrs Transmission Lubricant I I R 4 Yrs Tires Air Pressure I R Steering Components 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 l R Nuts Cap Screws Screws Bolts I I A Inj...

Page 8: ... from the air filter housing then remove the cotton fabric safety element using care not to allow dirt and debris to enter the engine DE008 4 Lightly tap the dry paper air filter to dislodge the dirt and dust Do not use compressed air 5 Insert a suitable light into the dry paper air filter and look for any pin points of light shining out of the filter medium A bright pin point of light indicates a...

Page 9: ...Periodic Maintenance Chart clean the spark arrester using the following procedure 1 Remove the three cap screws securing the spark arrester assembly to the muffler then loosen and remove the arrester CF105A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket is damaged in any way it must be replaced 3 Install the spar...

Page 10: ...e filter 6 Apply oil to a new filter O ring and check to make sure it is positioned correctly then install the new oil filter Tighten until contact is made then tighten an additional 3 4 turn DE018 NOTE Install a new O ring each time the filter is replaced 7 Install the engine drain plug and tighten to 18 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil fil...

Page 11: ... opening DE026A 3 Remove the transmission drain plug from the bot tom of the transmission and drain the lubricant into a drain pan DE016A 4 Install the drain plug and tighten securely Pour recommended lubricant into the filler hole Install the filler plug 5 Remove the transmission lubricant level stick and wipe it with a clean cloth then check the lubricant level with the level stick DE002A Front ...

Page 12: ...nts should be inspected periodically to ensure proper operation A Spline lateral movement slop B Coupling cracked damaged or worn Nuts Cap Screws Screws Bolts Tighten all nuts cap screws screws and bolts Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws screws and bolts are tight ened to specifications Injector Ti...

Page 13: ... floor so the headlights are approximately 6 1 m 20 ft from an aiming surface wall or similar aiming surface 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 make horizontal marks on the aiming surface 4 Make vertical marks which intersect t...

Page 14: ...E Error in the gear position icon indi cates no signal or a poor ground wire connection in the circuit Troubleshoot the harness connec tors gear shift position connector gear shift posi tion switch and LCD connector 4 Install the seat and left side engine cover Frame Welds Racks The frame welds and racks should be checked period ically for damage bends cracks deterioration broken components and mi...

Page 15: ... 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 brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKIN...

Page 16: ...g filled air may become trapped therefore elevate the rear of the ATV 30 40 cm 12 16 in to allow air to bleed from the filler neck Run the engine for several minutes then shut off the engine and fill with coolant to the top of the filler neck NOTE Use a good quality biodegradable glycol based automotive type antifreeze To check add coolant use the following procedure 1 Check the level of coolant i...

Page 17: ...t the drive face to prevent the weights from falling out Account for a spring seat spring bushing and lock washer DE096A DE094A 5 Thread one of the V belt cover screws into the fixed driven face and turn clockwise to open the driven pulley faces 6 Push the V belt down between the sheaves of the driven pulley approximately one inch then mak ing sure not to dislocate the one way clutch from the fixe...

Page 18: ...V belt cover gasket into position then install the cover and secure with the cap screws Tighten to 9 ft lb CD083 7 Secure the front fender to the footrest with the two cap screws Tighten securely 8 Install the right side footrest see Steering Frame Fuel Filter This diesel powered ATV is equipped with a high effi ciency fuel filter The fuel filter should be changed in accordance with the maintenanc...

Page 19: ...esistance is observed The sys tem will bleed itself through the tank return circuit 4 Check for any fuel leaks then start the engine and check for normal engine operation Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 20: ...0 20 mm 0 008 in Valve Guide Stem Clearance 0 015 0 060 mm 0 0006 0 0024 in Valve Guide Inside Diameter 7 005 7 020 mm 0 2758 0 2764 in Valve Stem Diameter 6 960 6 990 mm 0 2740 0 2752 in Valve Face Seat Width intake exhaust 1 6 2 0 mm 0 063 0 079 in Valve Spring Free Length min 43 0 mm 1 69 in CAMSHAFT AND CYLINDER HEAD Camshaft Lobe Height min intake exhaust 29 498 mm 1 161 in Camshaft Injection...

Page 21: ...se clamps securing the air diverter to the inlet hoses then remove the air diverter 7 Remove the upper radiator hose from the filler neck then loosen the hose clamp securing the filler neck to the thermostat housing and remove the filler neck DE073A NOTE Filler neck can remain attached to the overflow recovery hose 8 Remove the upper radiator hose from the radiator 9 Remove the four cap screws sec...

Page 22: ... hoses from the fuel rail DE065A 13 Disconnect the wire connectors from the tempera ture sensor oil pressure sensor gear shift position switch connector and voltage regulator then dis connect the starter solenoid glow plug power wire and the alternator positive wire DE104A DE067A CAUTION The fuel rail connections are easily bent Use care when removing the hose clamps and hoses Manual Table of Cont...

Page 23: ...d then remove the exhaust pipe Account for a steel gasket 18 Place a suitable block between the oil pan and frame member then remove the front engine mount cap screw and nut Account for a flat washer DE089A DE086A 19 Remove the cap screw and nut from the upper right engine mount Account for a flat washer DE088A 20 Remove the nuts and cap screws from the left rear and right rear engine mounts Accou...

Page 24: ...er vicing without removing the engine To remove the transmission use the following procedure 1 Remove the inner front splash shields foot pegs and forward footwells see Steering Frame 2 Remove three cap screws securing the front pro peller shaft to the front differential input coupler 3 Remove four cap screws securing the rear propel ler shaft to the output drive flange 4 Remove the transmission l...

Page 25: ...emble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure SPEED GOVERNOR Removing Disassembling 1 Remove the timing belt see Left Side Compo nents in this section 2 Remove the air filter assembly then remove the valve c...

Page 26: ...ont camshaft support housing then remove the governor flyweight assembly Account for a small O ring DE245A DE277 8 Remove the control spool thrust bearing and thrust washer Note the order of disassembly and keep together and in order for assembling pur poses CAUTION Failure to rotate the engine away from TDC will leave the flywheel side piston in close proximity to the valves If the camshaft is ro...

Page 27: ...crews A and B and spring C then remove the governor fork pivot pin Account for an O ring NOTE Do not loosen or remove screws D or E or fuel delivery equalization will have to be per formed DE291A CAUTION Do not break the seal or turn the torque limiter adjuster screw Severe engine damage could occur Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowe...

Page 28: ...rn contact points or excessive pivot point wear DE247A 2 Inspect all springs links and pivot pins for proper tension excessive wear or loose fit DE254A DE256A 3 Inspect the control spool thrust bearing and thrust washer for scoring excessive wear or missing bearing rollers DE278A Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 29: ...he throttle control arm then place the manifold and gasket into position and secure with the seven cap screws Tighten securely DE258A DE248A 4 Install the fuel injector control rack making sure the slotted end engages the governor linkage sleeve then tighten the cap screws to 11 in lb DE534A 5 Connect the throttle linkage into the throttle con trol lever then secure with the E clip DE249A 6 Place ...

Page 30: ...e oil seal lightly coat the camshaft drive pulley flange with clean engine oil and install on the camshaft NOTE The camshaft drive pulley has a molded extrusion in the pulley bore that must engage the keyway in the camshaft DE574A 9 Secure the camshaft drive pulley to the camshaft with a washer and cap screw then using an appro priate holding tool tighten the cap screw to 59 ft lb Manual Table of ...

Page 31: ...bracket and air diverter with ducts DE074A DE516A 3 Use duct tape to cover the engine air intake boot to prevent dirt or debris from entering the engine 4 Disconnect the oil pressure switch connector from the switch located on the right side of the valve cover then remove the fuel lift pump see Lift Pump in Fuel Lubrication Cooling DE077B 5 Disconnect the crankcase breather hose from the right fro...

Page 32: ...ft then rotate the camshaft until one of the unit injector push rods is fully extended into the injector pump barrel DE275A DE404A 9 Place a holding pin into the injector pump barrel then rotate the camshaft until the second injector is fully compressed and install a holding pin DE328A 10 Remove the three nuts securing the rocker arm assembly to the cylinder head then using rubber bands bind the r...

Page 33: ...E246A 13 Remove the governor control spool thrust bear ing and thrust washer keeping all components in order of disassembly DE278A 14 Remove the camshaft end cover then gently slide the camshaft toward the flywheel end of the engine Rotate the camshaft slightly to prevent binding and hanging in the camshaft bores Account for the fuel pump eccentric bushing DE297A Manual Table of Contents For Disco...

Page 34: ...or excessive wear scoring or pitting DE524 5 Inspect rocker arms camshaft followers and rocker shaft for excessive wear broken or scored rollers or cracked rocker arm shaft supports DE546A DE547A DE528A CAUTION Make sure to support the camshaft while the journals are pulled clear of the journal bores or damage to journal bores may occur WARNING Always wear safety glasses when working with com pres...

Page 35: ...s to be disas sembled label all rocker arms for installing pur poses If the rocker arms are mixed up the complete overhead must be adjusted 9 After labeling rocker arms and supports remove components from the rocker arm shaft 10 Inspect the wear points on the rocker arm shaft and using a micrometer measure the shaft The mea surements must be within specifications DE542 11 Measure the inside diamet...

Page 36: ...he camshaft into the cylinder head being careful not to nick or jam journals or journal bores DE525 2 Install the lift pump eccentric bushing onto the cam shaft then install the camshaft end cover using a new O ring Tighten the cap screws securely DE540A DE297A 3 Insert the lift pump push rod and engage the eccen tric bushing then using a new sealing ring install the lift pump and tighten the moun...

Page 37: ...table holding tool tighten the cap screw to 59 ft lb DE262 8 Lubricate all rocker shaft components with clean engine oil then install the rocker arm assembly on the cylinder head making sure the injector push rods are correctly installed in their respective injectors DE529 AT THIS POINT If the cylinder head has been removed no more com ponents may be installed prior to installation on the engine b...

Page 38: ... head cap screws to 6 5 ft lb 14 Connect the fuel hoses to the fuel rail then con nect the crankcase breather hose DE295A 15 Connect the oil pressure switch connector to the oil pressure switch DE077B 16 Install the air filter assembly then remove the tape from the engine air intake boot and connect the air intake boot Tighten the boot clamp securely 17 Install the air diverter and connect the air...

Page 39: ... then remove the fuel rail Account for four O rings 9 Carefully remove the spring from the injection control rack then remove the Allen head pivot screws securing the injection control rack to the injection pump fuel controls DE292A DE327 10 Remove the injection control rack by carefully dis engaging it from the governor linkage sleeve DE534A 11 Rotate the engine until the injector lobe forces the...

Page 40: ...ng surfaces 2 Clean the unit injector with a soft wire brush being careful not to damage the injector tip DE565A 3 Measure the injector nozzle protrusion A Mea surement should be 6 80 7 05 mm 0 268 0 277 in Excessive protrusion may be corrected by installing supplemental washers available in 0 25 mm 0 001 in sizes along with the standard cop per washers B DE566A DE570A 4 Clean the fire ring sealin...

Page 41: ... in keeping them in place on the injector while installing 7 Install the injector in the cylinder from which it was removed taking care to avoid dropping the push rod into the engine DE571 8 Repeat steps 6 and 7 for the second injector if it was removed 9 Install the unit injector retainer nuts and tighten in five steps to 15 ft lb in 3 ft lb increments DE329 10 Rotate the engine clockwise to comp...

Page 42: ...n lb DE534B DE405A 14 Place a small bead of high temperature sealant on the fuel rail seal then carefully install the valve cover with a new gasket and oil return boot Using a crisscross pattern tighten the Allen head cap screws to 6 5 ft lb then tighten the two tamper proof torx head cap screws to 6 5 ft lb AT THIS POINT If injectors were serviced static injector timing must be set see Top Side C...

Page 43: ... hose clamps securely 20 Install the front body panel front rack and seat see Steering Frame VALVE CLEARANCE ADJUSTMENT NOTE If the engine has been disassembled pro ceed to step 4 If the primary objective is to adjust the valves use the following procedure 1 Remove the front rack and front body panel see Steering Frame 2 Remove the air filter assembly then disconnect the crankcase ventilator hose ...

Page 44: ...am nut A while holding the adjuster B then tighten the jam nut securely and check clearance C 8 Rotate the crankshaft clockwise 180 and repeat steps 5 7 on the other cylinder 9 Place a small bead of high temperature sealant on the fuel rail seal then carefully install the valve cover with a new gasket and oil return boot Using a crisscross pattern tighten the Allen head cap screws to 6 5 ft lb the...

Page 45: ...lve in place of the O ring DE572 DE444A 3 Connect a suitable container filled with clean die sel fuel to the supply fitting using an inlet hose then place a small cup under the bleed hose DE403B 4 Rotate the engine in the direction of rotation clockwise until the 2 flywheel side piston is at top dead center TDC on the compression stroke reference mark D aligned to TDC index mark A and valves close...

Page 46: ...jector timing is early If it is to the right injector timing is late A Rotate the engine to perfectly align reference mark D and 13 BTDC mark B then loosen the jam nut on the fuel injector timing adjust ment screw For late timing proceed to step B For early timing proceed to step C DE562A B While watching the bleed hose turn the adjust ment screw clockwise until fuel flow stops DE562B C While watc...

Page 47: ... see Left Side Compo nents in this section 4 Remove the unit injectors see Top Side Compo nents in this section 5 Remove the lift pump and lift pump push rod see Fuel Lubrication Cooling 6 Rotate the crankshaft to approximately 90 after top dead center ATDC DE240A DE275A 7 Turn the camshaft drive pulley until the camshaft and rocker arms are unloaded all rocker arms in valve closed position 8 Remo...

Page 48: ...ing a suitable valve spring compressor remove the valves marking their position for assembly NOTE It is recommended to keep all individual components in a set such as valve valve spring valve keepers spring holders and retainers to aid during assembling DE300 AT THIS POINT If the cylinder head is being removed to allow removal of engine block components no further dis assembling is required Procee...

Page 49: ...ting Cylinder Head Valves 1 Thoroughly clean the cylinder head in a non caus tic solvent then dry with compressed air AT THIS POINT The pre combustion chambers do not have to be removed for general service such as valve replace ment valve seat replacement or normal cylinder head service If the pre combustion chambers must be removed always replace them with new cham bers CAUTION Do not attempt to ...

Page 50: ...If measure ment is greater than specified the valve guide must be replaced 9 Check the valve seats for evidence of discolor ation cracks or loose fit in cylinder head as well as clean even contact area Replace any valve seats that show evidence of excessive wear or damage 10 Check the cylinder head for cracks loose rocker arm studs or loose injector hold down studs If cylinder head is cracked it m...

Page 51: ... chambers cylinder head being careful not to nick or scratch the cylinder head NOTE Non caustic solvents may be used to assist in carbon removal Dry with compressed air 2 Making sure any spacers shims are correctly installed place the pre combustion chamber into the cylinder head with the glow plug opening directed toward the glow plug bore NOTE To simplify installation orientation of the pre comb...

Page 52: ...ghten to 18 ft lb 6 Install the unit injectors see Fuel Lubrication Cooling 7 Install the governor linkage see Speed Governor in this sub section 8 Install the camshaft see Camshaft Rocker Arms in this sub section At this point the cylinder head is ready for installation on the engine block Installing 1 Prior to installing the cylinder head a head gasket of the correct thickness must be selected i...

Page 53: ...asket onto the cylinder deck aligning the gasket on the alignment pins then carefully install the cylinder head onto the engine block aligning the head to the index dowels Piston Protrusion Gasket Thickness Hole Number 0 82 0 91 mm 0 032 0 036 in 1 56 1 64 mm 0 061 0 065 in 1 0 92 1 01 mm 0 036 0 040 in 1 66 1 74 mm 0 065 0 069 in 2 1 02 1 10 mm 0 040 0 043 in 1 76 1 84 mm 0 069 0 072 in 3 CAUTION...

Page 54: ...d disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure TIMING BELT Removing 1 Remove the front rack then remove the front body panel see Steering Frame 2 Remove the negative battery cable from the bat tery 3 ...

Page 55: ...d DE269A 9 Check that the reference mark C on the timing belt drive pulley aligns with the reference mark D on the oil pump housing DE230A 10 Loosen the retaining nut on the timing belt idler pulley then loosen the belt and remove from the engine DE230B Inspecting 1 Check the timing belt for missing cogs cracks or bare cords showing Replace if any of the condi tions are present CAUTION Do not rota...

Page 56: ...rence mark B on the cylinder head NOTE If the camshaft or crankshaft has been rotated use the following procedure to safely realign the reference marks A Carefully rotate the crankshaft until the refer ence mark C on the timing belt drive pulley is approximately 90 from the reference mark D on the oil pump housing DE275B B Rotate the camshaft to align the reference marks A and B then rotate the cr...

Page 57: ... the timing belt cover and secure with the existing hardware then install the crankshaft pul ley making sure the alignment pin is correctly located DE214B 7 Install the four cap screws and finger tighten then install a suitable holding fixture DE213 8 Apply blue Loctite 243 to the crankshaft pulley retaining cap screw and tighten to 260 ft lb DE212 9 Tighten the four cap screws from step 7 to 9 ft...

Page 58: ... 3 Install the timing belt see Left Side Components in this section 4 Fill the cooling system with coolant see Fuel Lubrication Cooling 5 Check for coolant leaks and proper coolant level OIL PUMP CRANKSHAFT SEAL Removing 1 Remove the timing belt see Left Side Compo nents in this section 2 Remove the timing belt drive pulley Account for a key DE226 3 Remove the screws securing the oil pump to the e...

Page 59: ... proceed to Installing Installing 1 Clean all gasket material from the surface of the engine block 2 Make sure the oil pump drive key in the crankshaft is in the 3 o clock position then locate the oil pump inner rotor keyway in the 3 o clock position as viewed from the crankshaft seal DE265A DE237A 3 Install two alignment bolts in the engine block then install a new oil pump gasket into position o...

Page 60: ... and the pivot bolt B then remove the alternator drive belt DE519C DE103C 4 Remove the adjuster cap screw and pivot bolt and remove the alternator Servicing NOTE The alternator regulator is not a service able part therefore it must be replaced as an assembly Installing 1 Place the alternator regulator into position on the engine then secure with the existing hardware Do not tighten at this time 2 ...

Page 61: ...the starter to the V belt housing then remove the starter DE102A 4 Remove the PTO flywheel then remove four countersunk cap screws securing the V belt hous ing to the engine block and remove the V belt housing DE109 DE114A Inspecting 1 Inspect the V belt housing for cracks elongated mounting hoses or loose alignment pins 2 Inspect the flywheel ring gear assembly for worn or broken teeth cracks or ...

Page 62: ...l then gently tap the gear down until firmly seated DE594 Installing 1 Using a new gasket secure the V belt housing to the engine block with the four countersunk cap screws tightened to 25 ft lb then install the fly wheel PTO shaft on the crankshaft and using the pattern shown tighten the five cap screws to 40 ft lb DE114A DE109A 2 Install the starter and tighten the cap screws to 35 ft lb DE102A ...

Page 63: ...s Account for a washer on each end DE122A 6 Remove the nut securing the shift cam detent stop per spring assembly then remove the assembly and account for a spring and washer DE123 7 Remove the speed sensor housing then remove the snap ring securing the rotor and remove the rotor Account for two alignment pins a gasket and two snap rings DE126A 8 From the right side remove the cap screws secur ing...

Page 64: ...to the output driven bevel gear NOTE Note the location of the bearing alignment pin on the front output driveshaft bearing DE663D 11 Remove the shift fork shaft B then remove the high low shift fork 12 Remove the shift shaft C and account for a spacer and washer DE677A 13 Remove the low reverse shift fork then remove the input driveshaft D NOTE The shift forks are identical therefore they may be u...

Page 65: ...ring the output drive bearing in the right side case then using appropri ate bearing drivers remove the appropriate bear ings DE169 DE170 Disassembling Driveshaft Drive Bevel Assembly NOTE Steps 1 18 of the preceding sub section must precede this procedure 19 Remove the retaining C rings in the output yoke then using an appropriate universal joint service tool separate the front drive yoke and bea...

Page 66: ...f the preceding sub sections must precede this procedure 22 Remove the high driven gear then remove the high low shift dog Account for a washer and the high driven gear bearing and bushing DE150A DE191A 23 Remove the thrust washer and countershaft drive gear from the opposite end of the countershaft DE150A DE151 24 Remove the reverse dog retaining snap ring then remove the reverse dog and reverse ...

Page 67: ... gear locking washer then rotate and remove the splined low gear retainer DE184 27 Remove the low gear Account for a washer and the low gear bearing and bushing DE155 Inspecting 1 Inspect all shafts for excessive wear worn splines bearing surface discoloration or chipped gears DE158A Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 68: ...tion chip ping or galling DE143 DE179 4 Inspect roller bearings for chipping missing roll ers or discoloration DE178 DE185 5 Inspect drive and driven bevel gears for proper tooth contact chipping or discoloration of gear teeth worn or chipped splines and bearing smoothness DE657 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 69: ... or broken spring DE128 11 Inspect bearings for discoloration flaking or roughness and binding when turning 12 Inspect and thoroughly clean all bearing pockets thread bores and plug openings to remove any metal filings or dirt accumulations DE171A 13 Clean all parts to be used for assembling in parts cleaning solvent then dry with compressed air Assembling Countershaft 1 Place the thrust washer on...

Page 70: ...ll the reverse driven gear onto the bearing then secure with a splined washer and snap ring NOTE Always install snap rings with the flat sharp side away from the washer DE186 5 Install the reverse shift dog and splined bushing onto the shaft then secure with a snap ring DE187A 6 Install the countershaft drive gear and thrust washer 7 Install the high low shift dog with the raised lugs directed tow...

Page 71: ...o establish correct gear tooth contact If only the secondary output driven gear or shaft are replaced proceed to Correcting Backlash in this sub section DE655A DE659A 1 Place the spacer on the output shaft then press the secondary output driven gear onto the output shaft until it firmly contacts the spacer DE667A AT THIS POINT If the drive bevel gear assembly or secondary output shaft assemblies w...

Page 72: ...veral rotations in both directions Gear contact should center between the root and top of gear teeth DE657A 7 To adjust tooth contact use the following chart to correctly shim the secondary bevel drive gear 8 After correct tooth contact is established proceed to Checking Backlash in this sub section Checking Backlash 1 If removed install the secondary drive bevel gear shaft into the transmission c...

Page 73: ...t shaft threads then using new nuts tighten the output drive shaft nut to 80 ft lb and the output drive yoke nut to 72 ft lb Assembling Gear Case 1 Install new bearings and seals in the left side and right side cases as required DE170 DE169 2 Install the reverse idler gear making sure to install a washer on each side of the gear then install the input driveshaft DE179 DE140 DE192A 3 Install the as...

Page 74: ...ment ring with the groove in the gear case and rotate the bearing to locate the bear ing anchor pin in the slot then align the groove in the rear bearing with the case groove and install the C ring DE135A DE663D 7 Apply a thin layer of Three Bond Sealant to the mating surface of the right side gear case then make sure that the alignment pins and washers are positioned as shown and join the gear ca...

Page 75: ...DE125 10 Install the gear shift cam plate cam arm stopper and gear shift sub shaft as shown making sure to align the timing marks Tighten all fasteners securely DE121A 11 Using a new gasket install the shift shaft housing and secure with existing cap screws then install the shift arm aligning the mark with the slot Tighten all fasteners securely DE119 12 Apply Three Bond Sealant to the secondary o...

Page 76: ...chnician should use discretion and sound judgment ENGINE BLOCK ASSEMBLY Removing 1 Remove the engine transmission assembly see Removing Engine Transmission in this section 2 Separate the transmission and V belt housing from the engine see Right Side Components in this section 3 Remove the timing belt see Left Side Compo nents in this section 4 Remove the cylinder head assembly see Top Side Compone...

Page 77: ...n rotate the crankshaft so that one connecting rod is at bottom dead center BDC DE580 DE440A 10 Remove the two cap screws from the connecting rod cap and remove the cap Account for one bear ing insert DE600 11 Rotate the crankshaft carefully until the second connecting rod is at BDC then using a large wooden dowel or hammer handle carefully push against the first connecting rod until the piston co...

Page 78: ...crews keeping the assem blies together 16 Use an appropriate thickness gauge to measure the crankshaft end play at the thrust bearing surface Record this measurement DE435A 17 Mark the main bearing caps and engine block for proper orientation then remove the cap screws securing the main bearing caps to the main bearing saddles in the engine block CAUTION The connecting rod and connecting rod cap a...

Page 79: ...hould be supported in the three main bearing journal locations or stood on the flywheel end Do not drop or strike the crankshaft 20 Set main bearing caps with inserts into the main bearing saddles and install cap screws Finger tighten only DE605 Cleaning and Inspecting 1 Clean all gasket material sealant varnish and car bon from the engine block mating and sealing sur faces DE338 2 Remove the main...

Page 80: ...linder head clearance To determine if the cylinder deck can be planed use the following procedure A Determine the maximum cylinder deck varia tion Vd B Add the deck variation Vd to the piston pro trusion Pp determined during removing Vd Pp to determine final piston protrusion Ppf Vd Pp Ppf C Compare the final piston protrusion Ppf to the chart to determine if gaskets are available that would allow...

Page 81: ... any measurement point the cylin der s must be bored Oversized pistons rings are available in 0 50 mm 0 020 in and 1 00 mm 0 039 in sizes DE369 DE350 8 Using a suitable ridge reamer tool clean the top of the cylinder bore then using a ball hone hone the cylinders to produce a 45 55 cross hatch NOTE To produce the proper 45 55 cross hatch pattern use a low RPM drill 600 RPM at the rate of 25 stroke...

Page 82: ...nkshaft journals with clean oil If no machining is required set aside until assembly DE620A 13 Remove the main bearing caps from the main bearing saddles then install the bearing inserts into the correct locations DE376 14 Install the main bearing caps and tighten to 44 ft lb then being careful not to mar the inserts mea sure the main bearing bores using an appropriate inside micrometer snap gauge...

Page 83: ...352 19 Using an appropriate inside micrometer measure the inside diameter of the connecting rod bearing insert It must be within specifications or the bear ings or connecting rod must be replaced DE612 20 Measure the inside diameter of the connecting rod piston pin bushing It must be within specifica tions CAUTION If a vise is used to secure the connecting rod it must have brass copper or hardwood...

Page 84: ...d The piston pins must measure within specifications DE351 24 Making sure pistons are clean and ring lands are free of carbon deposits measure ring to ring land clearance using new piston rings If ring to ring land clearance is excessive new pistons must be installed DE367 25 Using a suitable outside micrometer measure pis ton skirt diameter at a distance of 9 mm 0 350 in from the bottom of the sk...

Page 85: ...e to hold them in place DE628A 3 Install the lower main bearing inserts into the main bearing caps then install the thrust bearing inserts into the rear main bearing cap using oil soluble grease to hold in place DE431 4 Apply a liberal amount of clean engine oil to the crankshaft main bearing journals and the main bearing saddles then carefully install the crank shaft into the engine block Class C...

Page 86: ... Tool or shim stock then install the main bearing cap screws DE336 8 Install the center main bearing cap and finger tighten the cap screws DE335B 9 Tighten the main bearing caps to 44 ft lb in 7 ft lb increments DE335 10 Rotate the crankshaft to make certain that no bind ing exists 11 If pistons were removed from connecting rods install the pistons onto the connecting rods making sure the piston p...

Page 87: ...h the expander spring ends B Install the 2nd middle compression ring in the middle ring groove with the TOP or UP mark ings on the ring directed toward the top of the piston C Install the 1st top compression ring in the top ring groove with the TOP or UP markings on the ring directed toward the top of the piston NOTE The top compression ring is full chrome silver and the middle compression ring ha...

Page 88: ...to the crankshaft journal push or bump the top of the piston until the connecting rod is seated on the crankshaft DE436 21 Apply clean engine oil to the crankshaft journal and connecting rod cap bearing insert then mak ing sure the connecting rod cap is correctly ori ented to the connecting rod install the rod cap and secure with the cap screws Tighten to 29 ft lb in 7 ft lb increments CAUTION NEV...

Page 89: ...ew O rings on the oil sump and return pipes then apply oil soluble grease on the O rings and place the oil pan into position DE596A 28 Secure the oil pan with the Allen head cap screws and the two hollow studs and spacers making sure to install the two hollow studs at the outside cor ners on the crankshaft pulley side then using a crisscross pattern tighten to 7 ft lb DE442A 29 If the oil pan cove...

Page 90: ...nection to the transmission secondary transmis sion 35 Install the engine transmission assembly see Installing Engine Transmission in this section Installing Engine Transmission NOTE Arctic Cat recommends that new gaskets and O rings be installed whenever servicing the ATV NOTE If the engine transmission was removed as an assembly proceed to Engine Transmission in this sub section If only the tran...

Page 91: ... if directional arrows are present DE479 DE488 6 Secure the driven pulley with a flat washer and nut then tighten the nut to 125 ft lb 7 Install the movable drive clutch face and V belt cover see Checking Replacing V Belt in Periodic Maintenance Tune Up ENGINE TRANSMISSION 1 Attach a suitable lift and place the engine trans mission assembly into the frame from the left side tilting the engine forw...

Page 92: ...E083A 5 Raise the front of the engine and install a cap screw two flat washers and a nut securing the front mounting bracket to the front engine mount Do not tighten at this time DE087A 6 Install the cap screws washers and nuts in the left rear right rear and upper right engine mounts DE085A DE090A DE088A 7 Tighten lower engine mounting cap screws and nuts to 20 ft lb and upper engine mount to 35 ...

Page 93: ... Do not tighten the nuts at this time DE587 11 Install the muffler and secure to the exhaust pipe with two springs making sure the grafoil seal is in place then tighten the exhaust pipe nuts to 14 ft lb DE586 12 Connect the wiring connectors to the temperature sensor oil pressure sensor gear shift position switch connector and voltage regulator then con nect the starter solenoid glow plug power wi...

Page 94: ...ng bolts securely DE078B 15 Install the V belt cooling fan assembly then install the V belt cooling boots to the V belt housing DE076A 16 Connect the V belt cooling fan connector DE518A 17 Install the air filter assembly and secure with four cap screws then connect all hoses and secure with hose clamps Tighten all hardware securely Manual Table of Contents For Discount Arctic Cat Parts Call 606 67...

Page 95: ...071A DE066A 21 Connect the shift linkage to the transmission shift arm and secure with the E clip DE064A 22 Install the front body panel and front rack then install the left and right footrests see Steering Frame 23 Pour the recommended coolant engine oil and transmission lubricant into the respective filler necks see Periodic Maintenance Tune Up 24 Install the battery and connect the positive bat...

Page 96: ... System Fuel Solenoid Problem Engine stalls easily Condition Remedy 1 Valve clearance out of adjustment 1 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 5 Cam followers worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replace camshaft 5 Replace...

Page 97: ... 1 Replace springs 2 Adjust timing 3 Replace cams arms 4 Clean replace element 5 Clean replace hose 6 Replace fuel pump 7 Replace filter Problem Exhaust smoke dirty or heavy Condition Remedy 1 Oil in the engine overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored scuffed 5 Valve stems worn 6 Stem seals defective 7 Air cleaner element obstructed 1 Drain ex...

Page 98: ...ning 9 Thermostat stuck closed 10 Radiator hoses cap damaged obstructed 1 Clean replace air filter 2 Add oil 3 Drain replace fuel 4 Replace pump 5 Clean circuit 6 Fill examine system for leaks 7 Check fan fuse replace fan 8 Replace fan switch 9 Replace thermostat 10 Clear obstruction replace hoses Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerp...

Page 99: ...bustion chamber Fuel in excess of the amount required for any particu lar power setting is directed back into the fuel return side of the fuel rail and routed back to the fuel filter head where it either recirculates or is returned to the fuel tank via the fuel return hose Fuel flow is shut off when the ignition switch is turned to the OFF position A fuel solenoid valve is located on the fuel filt...

Page 100: ...oid see Electrical System if it is determined that replace ment is necessary use the following procedure REMOVING 1 Remove the right front inner splash panel then remove the V belt cooling boot from the V belt housing DE061A 2 Locate the fuel solenoid mounted on top of the fuel filter head then disconnect the spade connec tor from the solenoid DE647B 3 Remove the banjo fitting bolts A and B and re...

Page 101: ...move the fuel tank CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Remove the fuel level sensor and fuel pick up screen Account for a seal 2 Completely drain all contaminated fuel from the fuel tank then thoroughly wash the tank out with hot soapy water 3 Dry the tank interior with compressed air NOTE Repeat steps 2 and 3 un...

Page 102: ... see Engine Transmission Specifications 1 Connect the Tachometer to the engine 2 Disconnect the oil pressure switch connector then connect the Oil Pressure Test Kit to the oil pres sure switch port DE077B NOTE Some oil seepage may occur when install ing the oil pressure gauge Wipe up oil residue with a cloth 3 Start the engine and run at the recommended RPM The oil pressure gauge must read as spec...

Page 103: ...rom the main wiring harness then remove the radiator fan assembly and account for the grommets and collars 7 Remove the fan fan shroud assembly from the radiator CC863 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Flush the radiator with water to remove any con taminants 2 Inspect the radiator for leaks and damage 3 Inspec...

Page 104: ...er inlet Secure with the two hose clamps 3 Slide the upper hose onto the thermostat housing and radiator Secure with the two hose clamps 4 Install the lower coolant hose onto the water pump housing and radiator Secure with the two hose clamps 5 Fill the cooling system with the recommended amount of antifreeze Check for leakage Fan REMOVING 1 Remove the radiator see Radiator in this section 2 Remov...

Page 105: ...eads less than specified voltage charge the battery using the following guide lines A When using an automatic battery charger always follow the charger manufacturer s instructions B When using a constant current battery char ger use the following Battery Charging Chart NOTE If the battery voltage is 11 5 DC Volts or less some chargers may cut off and fail to charge If this occurs connect a fully c...

Page 106: ...gine will stop C Reverse switch reverse indicator light will illu minate D Hi Lo switch headlight beam bright and dim E Brake switches rear brakelight will illuminate 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 tes...

Page 107: ...ck tester lead to ground AR622D 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse switch or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good proceed to test the switch component the connector and the switch wiring harness for resistance RESISTANCE Switch Connector NOTE The brake lever must b...

Page 108: ...ld read 460 ohms 6 When the temperature reaches 50 C 122 F the meter should read 320 ohms 7 Remove the meter lead from the thermistor pin and connect to the switch pin then continue to heat the oil 8 When the temperature reaches approximately 110 C 230 F the meter should read less than 1 ohm Glow Plug Controller Relay The glow plug controller relay is a plug in device located under the seat The gl...

Page 109: ...ing harness NOTE If the meter shows battery voltage the main wiring harness is good The connector should be checked for resistance RESISTANCE Fan Motor Connector 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the blue wire then connect the black tester lead to the black wire AR645D 3 The meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resi...

Page 110: ...positions The relays are interchangeable NOTE The module and wiring harness are not a serviceable component and must be replaced as an assembly Electronic Speedometer Speed Sensor NOTE Prior to testing the speed sensor inspect the three wire connector on the speed sensor for contamination broken pins and or corrosion 1 Set the meter selector to the DC Voltage position 2 With appropriate needle ada...

Page 111: ...d tester lead to the red wire and the black tester lead to the brown wire With the switch in the ON position the meter must show 980 1020 ohms NOTE If the meter shows more than 1 ohm of resistance troubleshoot or replace the switch component the connector or the switch wiring harness Handlebar Control Switches The connector is the yellow one next to the steering post To access the connector the st...

Page 112: ...onnect the red tester lead to the orange wire then connect the black tester lead to the green white wire 3 With the selector switch in the 4WD position the meter must show less than 1 ohm 4 Connect the black tester lead to the black wire then select the 4WD LOCK position The meter should show less than 2 ohms NOTE If the meter does not show as specified replace the front drive selector switch VOLT...

Page 113: ...ore replacing the starter troubleshoot the starter volt age starter relay neutral start and start in gear relays To replace the starter use the following procedure REMOVING 1 Remove the negative battery cable from the bat tery 2 Remove the left side inner fender splash panel then remove the seat and the left side engine cover 3 Disconnect the battery cable and the starter wire from the starter sol...

Page 114: ...e two wire plug from the starter relay then connect the red tester lead to the green wire and the black tester lead to the black wire 5 Depress the starter button and observe the multim eter NOTE If battery voltage is indicated replace the starter relay If no voltage is indicated check Neu tral Start relay see Fuse Block Power Distribution Module in this section Alternator Regulator TESTING Prior ...

Page 115: ... battery 5 Install the left side engine cover and seat making sure the seat latches securely Headlights The connectors are the four 2 prong ones secured to the front bumper supports two on each side with cable ties BULB VERIFICATION Low and High Beam NOTE Perform this test on each headlight bulb Also a 12 volt external power supply w jumpers will be needed 1 Disconnect the wiring harness from the ...

Page 116: ...rake lever hand and brake pedal auxiliary are properly adjusted for this procedure 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the red blue wire then connect the black tester lead to the black wire 3 With either brake applied the meter must show battery voltage NOTE If the meter shows no voltage inspect bulb fuses wiring harness connectors and switches Fuel...

Page 117: ...ring connections loose disconnected 1 Charge replace battery 2 Replace switch 3 Replace starter assembly 4 Replace relay 5 Turn on switches 6 Connect tighten repair connections Problem Battery discharges too rapidly Condition Remedy 1 Battery sulfided 2 Electrical system excessively loaded 3 Charging system not charging 1 Replace battery 2 Reduce load 3 Replace alternator tighten alternator belt P...

Page 118: ...s located on the left 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 Elec trical System If the actuator runs constantly or makes squealing or grinding sounds the actuator must be replaced REMOVING 1 Remove the front inner fe...

Page 119: ...ing 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 then install the inner fender panel Front Differential NOTE To remove the rear gear case see Rear Gear Case in t...

Page 120: ...0 Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft then using a rubber mallet tap the end of the axle and free it from the knuckle assembly AF628D 11 Pull the steering knuckle away from the axle KX151 12 Support the axle to not allow it to drop or hang 13 Remove the lower shock bolts Account for the lock nuts then move the shocks aside and secure ...

Page 121: ...er panels 17 Using a T 30 torx wrench remove the three screws securing the front drive actuator to the gear case then remove the actuator AG925 18 Remove the lower differential mounting cap screw Account for a lock nut and washers CD026 19 Remove the upper differential mounting cap screws CAUTION Do not attempt to use a slide hammer or differential axle damage will occur Manual Table of Contents F...

Page 122: ... technician should use discretion and sound judgment 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing GC004A 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for assembling purposes GC015 CD106 3 Using a boot clamp pliers or suitable substitute remove the boot clamps then remove the...

Page 123: ... AF984 KX219 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside GC012 GC011 2 Install the input shaft seal making sure it is fully seated in the housing Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 ...

Page 124: ...the rear boot with an appropriate boot clamp CD112 CD099 5 Place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to 25 ft lb NOTE If a new gear case housing is being installed tighten the cap screws to 25 31 ft lb CD103 Disassembling Differential Assembly NOTE This procedure can be performed on a rear gear case 1 Using a T 40 torx wren...

Page 125: ...fferential lock assembly and set aside Note position of parts for assembling pur poses KX175 5 Remove the left differential bearing flange assem bly and account for a shim Mark the shim as left side KX177 KX178 6 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s and mark as right side KX179 KX181 Manual Table of Contents For Discount Ar...

Page 126: ...the pinion gear from the gear case housing CC878 3 Secure the pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar and a bearing CC879 4 Remove any reusable parts from the gear case housing then discard the housing and lock collar Assembling Pinion Gear 1 Install the bearing onto the pinion shaft Install the pinion shaft collar CC882 CC883 2 Place the p...

Page 127: ...e Shim Selection It is very important to adjust bevel gears for the proper running tolerances Gear life and gear noise are greatly affected by these tolerances therefore it is very important to properly adjust any gear set prior to final assembly The following procedure can be used on both front dif ferential or rear drive gear case NOTE All bearings must be installed in the gear case and the pini...

Page 128: ... the bearing flange is completely seated in the cover GC032A GC033A 4 Install the existing shim or a 0 063 in shim on the cover side of the ring gear then place the assem bled gear case cover onto the gear case and secure with three cap screws Tighten evenly using a crisscross pattern GC036B 5 Place the appropriate Backlash Gauge Tool into the splines of the ring gear and install a dial indica tor...

Page 129: ...h the cover side up then install a dial indicator contact ing the ring gear axle flange GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008 in 3 To increase end play decrease the shim thick ness To decrease end play increase the shim thickness NOTE Once proper backlash and end play are established the gear case can be assembl...

Page 130: ... 5 Making sure the O ring is properly positioned on the differential housing cover assembly install the cover with existing cap screws coated with green Loctite 609 Account for the ID tag Tighten the cap screws evenly to 23 ft lb NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new housing is being installed tighten the cap screws to 28 ft lb 6 Install the shift fork shaft...

Page 131: ...eat steps 1 2 for the opposite side INSTALLING DIFFERENTIAL 1 Align the splined input yoke with the front output splines then place the differential into position on the frame and install the cap screws washers and flex lock nuts Tighten to 38 ft lb Make sure the rubber boot is properly seated on the input yoke CD857 CD859 2 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid gear lubricant into the differ...

Page 132: ... lb then install and spread the cotter pins AF896D AF895D 9 Install the brake calipers and secure with new patch lock cap screws tightened to 20 ft lb AF894D 10 Install the wheels and tighten to 45 ft lb 11 Remove the ATV from the support stand Drive Axles REMOVING REAR DRIVE AXLE 1 Secure the ATV on a support stand to elevate the wheels WARNING Make sure the ATV is solidly supported on the sup po...

Page 133: ...shaft firmly toward the gear case to release the internal lock then while holding the axle in pull the CV cup from the gear case PR729B PR725A REMOVING FRONT DRIVE AXLE NOTE For removing a front drive axle see Front Differential in this section CLEANING AND INSPECTING NOTE Always clean and inspect the drive axle components to determine if any service or replace ment is necessary 1 Using a clean to...

Page 134: ...pin is flush to the hub nut CD027 7 Install the wheel Tighten to 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 50 ft lb 2 Place the brake hose into position on the upper...

Page 135: ...t the ring gear for excessive wear missing or chipped teeth or discoloration 2 Inspect the thrust button for excessive wear or dis coloration 3 Inspect the bearings for discoloration roughness or excessive wear NOTE For servicing bearings or seals see Front Differential in this section Installing Shimming NOTE Ring gear clearance must be adjusted prior to selecting shim for the thrust button 1 Ins...

Page 136: ...TV on a support stand to elevate the wheel then remove the wheel 2 Remove the cotter pin from the nut NOTE During assembly new cotter pins should be installed KX041 3 Remove the flange nut securing the hub 4 Remove the brake caliper PR243A 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 damag...

Page 137: ...re the ATV on a support stand to elevate the wheel then remove the wheel 2 Drain the brake fluid from the caliper hose and master cylinder through the bleed screw by pump ing the brake lever pedal PR235 WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service Failure to properly repair brake systems can result in loss of control causing severe injur...

Page 138: ... caliper and discard the O ring PR239B NOTE The O ring is used for shipping purposes and provides no function in operation 6 Cover the piston end of the housing with a shop towel then keeping fingers clear of piston travel apply compressed air to the fluid port to blow the piston free of the housing Account for two seal rings in the housing PR713A PR715 7 Using an appropriate seal removal tool car...

Page 139: ...brake fluid to the cylinder bore of the housing seals and brake piston PR715 PR717A 2 Press the piston into the caliper housing using hand pressure only Completely seat the piston then wipe off any excessive brake fluid PR711A PR712 3 Apply high temperature silicone grease supplied with the O ring kit to the inside of the caliper holder bores and O rings then install the four O rings into the cali...

Page 140: ... Up 9 Install the wheel Tighten to 45 ft lb 10 Remove the ATV from the support stand and ver ify brake operation CAUTION If brake pads become contaminated with brake fluid they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads Failure to do so will result in reduced braking and premature brake pad failure WARNING Never use brake fluid from an open container or reuse ...

Page 141: ...ars pinions 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 tr...

Page 142: ...AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Thoroughly clean all shock absorber components 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock rods sleeves bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber spring over the...

Page 143: ...p screws securing the ball joints to the knuckle AF628D 8 Tap the ball joints out of the knuckle then remove the knuckle 9 Remove the lower shock absorber eyelet from the upper A arm 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remove the snap ring from the ball joint then remove the ball joint from the A arm WARNING Make sure the ATV is solidly supported on the sup port sta...

Page 144: ...nstall the A arm assemblies into the frame mounts and secure with the cap screws Only fin ger tighten at this time AF610D 3 Route the brake hose through the upper A arm shock absorber mount then secure the hose to the A arm with a cable tie and grommet DE054A 4 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut to 50 ft lb 5 Secure the A arm assemblies to the frame mounts...

Page 145: ... the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut Release the brake lever lock 5 Remove the caliper right side only NOTE Do not allow the brake calipers to hang from their cable hose 6 Remove the cap screws and lock nut securing the shock absorber to the...

Page 146: ...r tighten at this time 2 Slide the knuckle onto the drive axle and into posi tion on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to 50 ft lb 3 Tighten the hardware securing the A arms to the frame mounts from step 1 to 50 ft lb 4 Apply grease on the drive axle splines then install the hub assembly onto the drive axle CD009 5 Secure the hub assembly wi...

Page 147: ...ents or bends 4 Inspect each tire for cuts wear missing lugs and leaks INSTALLING Install each wheel on its hub Tighten to 45 ft lb NOTE Make sure each wheel is installed on its proper hub as noted in removing the rotation arrow if applicable must indicate forward direc tion of rotation AF612D CHECKING INFLATING 1 Using an air pressure gauge measure the air pres sure in each tire Adjust the air pr...

Page 148: ...iodic Maintenance Tune Up 5 Increase the air pressure in the tires with the small est circumference measurement until all tires are equal in circumference 6 Repeat steps 4 5 as necessary to ensure proper handling Troubleshooting WARNING Do not operate the ATV if tire damage exists Problem Suspension too soft Condition Remedy 1 Spring s weak 2 Shock absorber damaged 3 Shock absorber preload too low...

Page 149: ...onnect any wires from instrument pod components CD759 2 Remove the reinstallable rivets securing the radia tor access cover and remove the cover CD666 3 Remove the reinstallable rivets securing the steer ing post cover and remove the cover 4 Unlatch the storage compartment lid then slide the storage compartment cover assembly forward and lift off 5 Remove the four cap screws securing the handle ba...

Page 150: ...nd steering post brackets for cracks bends or wear 6 Inspect the bearing halves bearing caps and bear ing housings for cracks or wear 7 Inspect the handlebar tube for cracks wear or unusual bends 8 Inspect the handlebar grips for damage or wear INSTALLING 1 Place the steering post into position then secure the lower bearing flange to the frame with two cap screws Tighten to 20 ft lb AL600D 2 Place...

Page 151: ...installing a grip use contact spray or alcohol to clean the inside of the grip and the handlebar of glue residue oil or any other con taminant 1 Apply a liberal amount of Handlebar Grip Adhe sive to the inside of the grip 2 Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up 3 Wipe off any excess glue then secure the grip with the handlebar plug an...

Page 152: ... into the knuckle PR287A 2 Install the knuckle to the upper and lower ball joints and secure with the two cap screws Tighten to 35 ft lb AF760D 3 Install the tie rod end and secure with the nut Tighten to 35 ft lb then install a new cotter pin and spread the pin NOTE During assembling new cotter pins should be installed AF759D 4 Apply a small amount of grease to the hub splines CAUTION Use extreme...

Page 153: ...ications 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 CD005 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 straight ahead position NOTE When measuring and adjusting there should be a normal operating l...

Page 154: ...hould be taken not to disturb the handlebar position 8 Using a permanent marker of some type mark the center of each front tire at a height parallel to the belly panel AF789D 9 Measure the distance between the marks at a height parallel to the belly panel at the front side then record the measurement 10 Push the ATV forward until the marks are parallel to the belly panel on the back side then meas...

Page 155: ...e fenders Tighten all hard ware securely Front Bumper Assembly REMOVING 1 Remove the two flange bolts and lock nuts secur ing the upper bumper supports to the bumper 2 Remove the through bolt and lock nut securing the bumper to the frame then remove the bumper CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all bumper ...

Page 156: ... side to separate the front panel lower fend ers from the left side and right side footwells CD691 CD682 7 Remove the shift knob retaining pin and remove the shift knob then remove the shift lever pivot axle nut and remove the axle and shift lever Account for a spring and two O rings CD779 CD780A 8 Disconnect four headlight connectors and secure the wires out of the way then disconnect the wires t...

Page 157: ...tate and lower into position CD765 2 Connect the headlight connectors to the appropri ate headlights and the front accessory plug wires to the accessory plug CD681 3 Make sure the rubber grommets and bushings are in place then place the front rack into position and secure with the screws and flange nuts Tighten securely 4 Install one cap screw and flange nut and four plas tic rivets on each side t...

Page 158: ...EANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the footrest using a pressure washer 2 Inspect the footrest weldments for cracks or unusual bends 3 Inspect all tubing for cracks or unusual bends INSTALLING 1 Secure the footrests to the frame with four cap screws and two flange nuts then tighten securely 2 Place the footw...

Page 159: ...ck Account for the bushings CD690A 2 Remove one shoulder screw and lock nut and three plastic rivets on each side securing the rear body panel to the footwells CD691A 3 Remove two machine screws securing the tool tray 4 Disconnect the battery negative cable first NOTE The battery does not have to be removed to remove the rear body panel 5 Disconnect the taillight brakelight then remove the fuel ta...

Page 160: ...ame 2 Remove the torx head cap screws securing the taillight assembly to the frame Account for any washers 3 Remove the taillight assembly INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect wiring harness three prong connector lens base cap screws and socket for damage 2 Inspect all wires for corroding pinching and cracking 3 Inspec...

Page 161: ...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 uneven Condition Remedy 1 Wheel hub bearings worn loose 2 Front wheel alignment incorrect 3 Tire inflation pressure incorrect 1 Replace bearings 2 Adjust alignment 3 Adjust pressure Problem Steering noise Condition Remedy 1 ...

Page 162: ...using by gently pressing it toward the pivot pin hole in the housing then lay it aside leaving the switch and wiring harness connected BC205 5 Remove the clamp screws securing the brake housing to the handlebar then remove the assem bly from the handlebar DE058A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the pin securing the...

Page 163: ...p ring BC206 4 Bleed the brake system see Periodic Mainte nance Tune Up Throttle Control REMOVING 1 Remove the two machine screws securing the throttle control to the handlebar 2 Slide the grommet out of the lower half of the throttle control then remove the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm to the throttle control lever AF67...

Page 164: ...INSTALLING 1 Place the shift rod into position on the engine shift arm and secure with the existing E clip 2 Using a new lock nut B secure the shift rod to the upper shift arm then using two open end wrenches tighten securely AF941A 3 Place the spring into position between the upper shift arm and shift lever then making sure the O rings are in place on the axle secure the shift lever to the arm wi...

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