Arctic Cat 2011 Prowler HDX Service Manual Download | Manualshive

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3-13

3



NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install a suit-
able connecting rod holder.

Servicing Top-Side

Components



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

VALVE ASSEMBLY

When servicing valve assembly, inspect valve seats,

valve stems, valve faces, and valve stem ends for pits,

burn marks, or other signs of abnormal wear.



NOTE: Whenever a valve is out of tolerance, it

must be replaced.

Cleaning/Inspecting Valve Cover



NOTE: If the valve cover cannot be trued, the cyl-

inder head assembly must be replaced.

1. Wash the valve cover in parts-cleaning solvent.

2. Place the valve cover on the Surface Plate covered

with #400 grit wet-or-dry sandpaper. Using light

pressure, move the valve cover in a figure eight

motion. Inspect the sealing surface for any indication

of high spots. A high spot can be noted by a bright

metallic finish. Correct any high spots before assem-

bly 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. Using a valve spring compressor, compress the valve

springs and remove the valve cotters. Account for an

upper spring retainer.

CC132D

2. Remove the valve seal and the lower remaining

spring seat. Discard the valve seal.

CC136D



NOTE: The valve seals must be replaced.

CAUTION

Do not allow the connecting rod to go down inside
the crankcase. If the rod is down inside the crank-
case and the crankshaft is rotated, severe damage
will result.



AT THIS POINT

To service piston, see Servicing Top-Side Compo-
nents sub-section.



AT THIS POINT

To service center crankcase components only, pro-
ceed to Removing Left-Side Components.

CAUTION

Do not remove an excessive amount of the sealing
surface or damage to the camshaft will result.
Always check camshaft clearance when resurfacing
the valve cover.

CAUTION

Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or dam-
age to the sealing surface may result.

Manual

Table of Contents

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Summary of Contents for 2011 Prowler HDX

Page 1: ...size important information The symbol WARNING identifies personal safety related information Be sure to fol low the directive because it deals with the possibility of serious personal injury or even death A CAUTION identi fies unsafe practices which may result in vehicle related damage Follow the directive because it deals with the possibility of damaging part or parts of the vehicle The symbol NO...

Page 2: ... Prowler HD er H TABLE OF CONTENTS 1 General Information Specifications 2 Periodic Maintenance Tune Up 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: ...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 4 Gasoline Oil Lubricant 1 4 Genuine Parts 1 5 Preparation For Storage 1 5 Preparation After Storage 1 5 Manual Table of Contents ...

Page 4: ...upport Frame 48 in lb 5 Front Rear ROPS Tube Arm Rest Steering Post Support 20 27 Top ROPS Support Front Rear ROPS Tubes 8 11 Rear ROPS Tube Lower ROPS Support 8 11 Shift Cable Shift Axle Arm 8 11 Shift Cable Mounting Adjuster Shift Cable 20 27 STEERING COMPONENTS Part Part Bolted To Torque ft lb N m Steering Wheel Steering Wheel Shaft 25 34 Steering Wheel Shaft Intermediate Shaft Upper 36 49 Inte...

Page 5: ...4 Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Tappet Cover Valve Cover 9 12 Crankshaft Spacer Crankshaft 28 38 Oil Pump Cover Crankcase 8 11 Oil Pump Drive Gear Crank Balancer Shaft 62 84 Output Shaft Flange Nut Output Shaft 62 84 Outer Magneto Cover Magneto Cover 8 11 Magneto Rotor Nut Crankshaft 105 143 Cam Sprocket Camshaft 11 15 Speed Sensor Housing Crankcase 8 11 V Belt Cover Crankca...

Page 6: ... Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded In many areas oxygenates either etha nol 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 necessary to add a gasoline antifreeze since ethanol will prevent the accumulation ...

Page 7: ...s holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 7 Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed cool ant 8 Disconnect the battery cables then remove the bat tery clean the battery posts and cables and store in a clean dry area 9 Store ...

Page 8: ...all calibrated nuts cap screws and bolts are tightened to specifications 9 Check tire pressure Inflate to recommended pres sure as necessary 10 Make sure the steering moves freely and does not bind 11 Check the spark plug Clean or replace as necessary CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system CAUTION Connect t...

Page 9: ...g Engine Compression 2 4 Spark Plug 2 5 Muffler Spark Arrester 2 5 Engine Transmission Oil Filter 2 6 Front Differential Rear Drive Lubricant 2 7 Driveshaft Coupling 2 7 Nuts Bolts Cap Screws 2 7 Headlight Taillight Brakelight 2 7 Shift Lever 2 8 Hydraulic Brake System 2 10 Burnishing Brake Pads 2 11 Checking Replacing V Belt 2 11 Troubleshooting Brake System 2 14 Manual Table of Contents ...

Page 10: ...ine Compression I Spark Plug I I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R Gas Hoses I I R 2 Yrs Throttle Cable Ends Accelerator Pedal Pivot I I C L A R Engine Transmission Oil Level I A Engine Transmission Oil Filter R 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 boots d...

Page 11: ...ill a wash pan larger than the element with a non flammable cleaning solvent then dip the ele ment in the solvent and wash it NOTE Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat 4 Dry the element 5 Put the element in a plastic bag then pour in air filter oil and work the element Reattach the filter to the filter screen NOTE Carefully squeeze excess oil from the ele ment 6 Cl...

Page 12: ... Rotating the valve adjuster dial counter clockwise will open the valve tappet clearance by 0 05 mm 0 002 in per mark E While holding the adjuster dial at the proper clearance setting tighten the jam nut securely with the valve adjuster handle 3 Install the spark plug then install the timing inspec tion plug 4 Place the two tappet covers with O rings into posi tion Tighten the cap screws securely ...

Page 13: ...rong spark keep the plug free of carbon ATV 0051 Adjust the gap to 0 7 0 8 mm 0 028 0 032 in ATV0052C When installing the spark plug be sure to tighten it securely A new spark plug should be tightened 1 2 turn once the washer contacts the cylinder head A used spark plug should be tightened 1 8 1 4 turn once the washer contacts the cylinder head Muffler Spark Arrester Clean the spark arrester using...

Page 14: ...sitioned correctly then install the new oil filter Tighten securely 5 Install the engine drain plug and tighten to 16 ft lb Pour the specified amount of the recommended oil in the filler hole HDX042A 6 Start the engine while the vehicle is outside on level ground and allow it to idle for a few minutes 7 Turn the engine off and wait approximately one min ute then unscrew the oil level stick and wip...

Page 15: ...maged or worn C Universal joints worn or missing bearings Nuts Bolts Cap Screws Tighten all nuts bolts and cap screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened to specifications Headlight Taillight Brakelight HEADLIGHT NOTE The bulb portion of the headlight is frag ile HANDLE WITH C...

Page 16: ...ersect the horizontal marks on the aiming surface directly in front of the headlights 5 Switch on the lights Make sure the HIGH beam is on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when the most intense beam is centered on the verti cal mark 5 cm 2 in below the horizontal mark on the aiming surface 0740 647 7 Using the adjuster knob adjust each headlight until correct aim...

Page 17: ...the proper icon illuminates on the LCD ADJUSTING PARK INDICATOR LIGHT 1 Remove the shift lever boot then shift the transmis sion into park NOTE Verify the transmission is in park by rock ing the vehicle It will not move if in park HDX177 2 Loosen the lower mounting nut on the shift cable several turns then while holding the shifter firmly against the park gate adjust the upper mounting nut against...

Page 18: ... clear hose onto one FRONT bleeder screw and direct the other end into a container then while holding slight pressure on the brake pedal open the bleeder screw and watch for air bubbles Close the bleeder screw before releasing the brake pedal Repeat this procedure until no air bubbles are present AF637D PR377C NOTE During the bleeding procedure watch the reservoir very closely to make sure there i...

Page 19: ... this section BRAKE DISC Using a micrometer measure the thickness of the brake disc in the contact surface If thickness is 0 125 in or less the disc must be replaced To replace the brake disc see Section 6 Hub Burnishing Brake Pads Brake pads must be burnished to achieve full braking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the bra...

Page 20: ...6A GZ085 INSTALLING 1 Place the V belt into position on the driven pulley and over the front shaft GZ085 NOTE The arrows on the V belt should point forward 2 Pinch the V belt together near its center and slide the spacer and movable drive face onto the driveshaft Secure the drive face with a washer and nut coated with red Loctite 271 Tighten the nut to 165 ft lb GZ485A CAUTION Make sure the movabl...

Page 21: ...e V belt is flush with the top of the driven pulley 4 Place the V belt cover gasket into position then install the cover and secure with the cap screws mak ing sure the different lengthed cap screws are in their proper location Tighten the cap screws to 8 ft lb 5 Install the seat seat back and seat base Manual Table of Contents ...

Page 22: ...luid low 2 Brake fluid incorrect 3 Piston seal cup worn 1 Add fluid to proper level 2 Replace with correct fluid 3 Replace seal cup Problem Brake fluid leaking Condition Remedy 1 Connection joints loose 2 Hose cracked 3 Piston seal worn 1 Tighten joint 2 Replace hose 3 Replace seal Problem Brake pedal spongy Condition Remedy 1 Air trapped in hydraulic system 2 Brake fluid low 1 Bleed hydraulic sys...

Page 23: ...3 1 3 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 Prowler HDX Table of Contents 3 6 Manual Table of Contents ...

Page 24: ...6 mm 27 9 mm Valve Tappet Clearance intake cold engine exhaust 0 1016 mm 0 1524 mm Valve Guide Stem Clearance intake exhaust 0 013 mm Valve Guide Valve Stem Deflection max wobble method 0 35 mm Valve Guide Inside Diameter 5 000 5 012 mm Valve Stem Outside Diameter intake exhaust 4 972 4 987 mm Valve Stem Runout max 0 1 mm Valve Head Thickness min 2 3 mm Valve Stem End Length mm 3 97 mm Valve Face ...

Page 25: ...t hose 2 Clean replace hose 3 Clean replace inlet screen valve screen 4 Replace fuel pump Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 ECU defective 4 Fuel injector obstructed 5 Valve clearance out of adjustment 1 Clean replace plug 2 Replace magneto 3 Replace ECU 4 Replace fuel injector 5 Adjust clearance Problem Engine noisy Excessive valve chatter Cond...

Page 26: ...orly Condition Remedy 1 Valve clearance out of adjustment 2 Valve seating poor 3 Valve guides defective 4 Rocker arms arm shaft worn 5 Magneto defective 6 ECU defective 7 Spark plug fouled gap too wide 8 Ignition coil defective 9 Fuel injector obstructed 1 Adjust clearance 2 Replace service seats valves 3 Replace guides 4 Replace arms shafts 5 Replace magneto 6 Replace ECU 7 Adjust gap replace plu...

Page 27: ...ust gap replace plug 9 Replace fuel injector 10 Clean element 11 Drain excess oil change oil 12 Tighten replace manifold 13 Replace cam chain sprockets 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 Intake manifold leaking air 7 Coolant level low 8 Fan malfunctioning 9 Fan switch...

Page 28: ...o allow removing of the center belly panel 1 Remove the seat seat back and seat base then remove the battery cover and disconnect the nega tive battery cable 2 Remove the center skid plate then drain the oil and coolant 3 Remove the center floorboard 4 Marking all nylon tie locations for installing pur poses from the right side disconnect the MAP sensor connector A fuel injector connector B ISC co...

Page 29: ...aside 9 From the left side disconnect the ECT sensor con nector speed sensor connector and spark plug cap HDX135A HDX137A 10 Remove the E clip from the shift arm then remove the cap screws securing the shift cable bracket to the engine case Remove the shift cable from the shift arm and engine HDX142A 11 Disconnect the starter cable from the starter then remove the cap screw securing the engine har...

Page 30: ...haust pipe Account for a gra foil seal in the cylinder head and a grafoil seal at the muffler HDX153A 15 Remove the cap screws securing the driveshafts to the front and rear engine flanges then disconnect the upper and lower coolant hoses HDX158A HDX159A 16 Disconnect the oil cooler lines and plug them to prevent oil spillage 17 Remove the nuts from the rear engine mounts then remove the front thr...

Page 31: ...g inspec tion plug then using an appropriate wrench rotate the crankshaft to top dead center of the compres sion stroke 1 Remove the two tappet covers CC001D NOTE Keep the mounting hardware with the cov ers for assembly purposes or thread them back into the head to keep them separated 2 Remove the 12 cap screws securing the valve cover to the head account for the four rubber washers on the top sid...

Page 32: ...nder head then remove the C ring NOTE Care should be taken not to drop the C ring down into the crankcase CC012D 5 Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft then drop the sprocket off the camshaft CC013D 6 While holding the chain slide the sprocket and cam shaft out of the cylinder head CC266D 7 Remove the cap screw securing the chain tensioner a...

Page 33: ...unt for two alignment pins then remove the cam chain guide CC020D CC022D C Cylinder D Piston NOTE Steps 1 9 in the preceding sub section must precede this procedure 10 Loosen the clamp securing the coolant hose to the union then detach the hose 11 Remove the two nuts securing the cylinder to the crankcase AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub secti...

Page 34: ...lip CC032D 14 Using the Piston Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston NOTE It is advisable to remove the opposite side circlip prior to using the puller CC033D AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub section CAUTION When removing the cylinder be sure to support the piston to prevent damage to the crankcase and pis t...

Page 35: ...on 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 Using a valve spring compressor compress the valve springs and remove the valve cotters Account for an upper spring retainer CC132...

Page 36: ...ace 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 Maximum runout must not exceed specifications Measuring Valve Guide Valve Stem Deflection Wobble Method 1 Mount a dial indicator and base on the surface plate then place the cylinder head on the surface plat...

Page 37: ...gs with the painted end of the spring facing away from the cylinder head NOTE If the paint is not visible install the ends of the springs with the closest wound coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor compress the valve springs and install the valve cotters CC132D PISTON ASSEMBLY NOTE Whenever a piston or pin is out of...

Page 38: ...n outside diameter at each end and in the center If measurement is not within speci fications the piston pin must be replaced ATV 1070 2 Insert an inside dial indicator into the piston pin bore The diameter must not exceed specifications Take two measurements to ensure accuracy ATV 1069 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder front to back in six places CC127D 2 Measure th...

Page 39: ...rface plate covered with 400 grit wet or dry sandpaper Using light pressure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assem bly by continuing to move the cylinder head in a fig ure eight motion until a uniform bright metallic finish is attained CC128...

Page 40: ...ements for a total of six measurements The trueness out of round ness is the difference between the highest and low est reading Maximum trueness out of roundness must not exceed specifications CC127D 2 Wash the cylinder in parts cleaning solvent 3 Inspect the cylinder for pitting scoring scuffing and corrosion If marks are found repair the surface using a 320 grit ball hone NOTE To produce the pro...

Page 41: ...ce a strip of plasti gauge in each of the camshaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap screws Tighten securely NOTE Do not rotate the camshaft when measur ing clearance 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve cover and cam shaft CC003D 5 Match the width of the plasti gauge with th...

Page 42: ...ton skirt and square the piston in respect to the crankcase CF083 3 Lubricate the inside wall of the cylinder then using a ring compressor compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crankcase CC024D 4 Loosely install the two nuts which secure the cylin der ...

Page 43: ...m step 8 in 10 ft lb increments to 40 ft lb then tighten the 8 mm nut from step 9 to 18 ft lb Using a crisscross pattern tighten the 6 mm nuts from step 9 to 8 ft lb Tighten the two cylin der to crankcase nuts from step 4 securely 11 With the timing inspection plug removed and the chain held tight rotate the crankshaft until the piston is at top dead center 12 Install the rear cam chain tensioner ...

Page 44: ...ole in the sprocket then place the cam shaft sprocket assembly onto the cylinder ensuring the following CF013A A Piston still at top dead center B Camshaft lobes directed down toward the pis ton C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned...

Page 45: ...012D 21 Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside GZ162A 22 Remove the cap screw from the end of the chain ten sioner then using a flat blade screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clo...

Page 46: ...nder head and valve cover CC275D 27 Place the valve cover into position NOTE At this point the rocker arms and adjuster screws must not have pressure on them 28 Install the four top side cap screws with rubber wash ers then install the remaining cap screws Tighten only until snug CC003D 29 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 28 to 8...

Page 47: ...ount for the gasket 2 Remove the flange nut securing the spacer to the crankshaft then remove the spacer Account for the O ring PR465 3 Using a cold chisel scribe a mark showing the rela tive position of the shift arm to the shift arm shaft to aid in installing then remove the shift arm PR429A 4 Remove the two cap screws securing the speed sen sor housing then remove the housing Account for the ga...

Page 48: ...right side cover for any shaft washers that may have come off with the cover Make sure they are returned to their respective shafts and the starter idler gear spacer is on the shaft or in the cover CF075A 9 Remove the nut securing the magneto rotor to the crankshaft then install the magneto rotor puller adapter NOTE The puller has left hand threads 10 Using Magneto Rotor Remover Set with appropria...

Page 49: ... the driven gear and drive gear Failure to do so could result in the loss of an alignment pin into the crankcase 14 Remove the shift shaft noting the timing marks for assembling purposes Account for two washers PR430A 15 Remove the gear shift cam plate then remove the shift cam stopper and cam stopper spring Account for two washers PR434A Installing Left Side Components NOTE Plug the oil passage i...

Page 50: ...nap ring should be facing outward NOTE Once the gears are secured remove the oil passage plug from the crankcase 3 Install the two starter gear shafts then install the two starter gears with the beveled side of the intermedi ate gear facing inward as noted in removing CD139 PR447A 4 In order on the crankshaft install a washer ring gear key and the magneto rotor Secure with the nut threads coated w...

Page 51: ...h two washers making sure to align the timing mark on the shift shaft with the mark on the shift cam plate CD954A CD927A 8 Lubricate the magneto cover gasket with fresh engine oil then place it into position on the two alignment pins Make sure the outer shift shaft washer is in place PR431A 9 Install the magneto cover and secure with the cap screws Tighten only until snug 10 Place the spacer into ...

Page 52: ...ing are aligned Tighten securely 17 Place the gasket and outer magneto cover into posi tion on the side cover then tighten four screws to 8 ft lb Right Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmissio...

Page 53: ...intake plate then remove the plate cushion PR393 6 Remove the cap screws securing the clutch cover Note the location of the different lengthed cap screws for installing purposes Using a rubber mallet carefully remove the cover Account for two align ment pins CD973A CD974A NOTE For steps 7 13 refer to illustration PR398B NOTE To aid in installing it is recommended the assemblies are kept together a...

Page 54: ...inspect the clutch hous ing seal CF088A 9 Remove the two Allen head screws securing the gear position switch then remove the sensor Account for two neutral contact pins and two springs CD997 10 Remove the nut left hand threads securing the clutch shoe assembly C FI279A 11 Remove the cap screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer KEY A Oil Pump Driven Gea...

Page 55: ...ing securing the oil pump driven gear A then remove the gear noting the direction of the sides of the gear for installing purposes Account for a pin and a washer CD984 CD895A 14 Remove the cap screws securing the oil pump then remove the pump CD988 Servicing Right Side Components NOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary Manual...

Page 56: ...both directions the drive assembly must be replaced INSPECTING OIL PUMP 1 Inspect the pump for damage 2 It is inadvisable to remove the screw securing the pump halves If the oil pump is damaged it must be replaced CD988A DRIVEN PULLEY NOTE The driven pulley is a non serviceable component If pulley faces cam ramps or sheave bushings are worn the assembly must be replaced Do not to disassemble the d...

Page 57: ...ew threads coated with red Loctite 271 and the washer Tighten the cap screw to 62 ft lb CD992 CD991 5 Grease the driven gear pin and insert it into the oil pump shaft then install the driven gear noting the direction of the sides of the gear from removing Secure with a snap ring CD985A CD984 NOTE When installed correctly the sides of the drive and driven gears will be flush with each other 6 Insta...

Page 58: ...tch cover install the clutch housing into the cover using a rubber mallet 11 Place the clutch cover clutch housing assembly into position on the crankcase then secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighten to 8 ft lb CF086 12 Place the air intake plate cushion into position then install the air intake plate Tighten the cap screws thre...

Page 59: ...NOTE At this point the cap screw can be removed from the driven pulley face 18 Rotate the V belt and driven pulley clutch until the V belt is flush with the top of the driven pulley 19 Place the V belt cover gasket into position then install the cover and secure with the cap screws mak ing sure the different lengthed cap screws are in their proper location Tighten the cap screws to 8 ft lb CD083 C...

Page 60: ... 7 refer to illustration CC821B CC821B NOTE To aid in installing it is recommended the assemblies are kept together and IN ORDER 1 Remove the secondary driven shaft assembly A noting the location of the bearing locating pins Account for the bearing C ring CD267 2 Remove the reverse idler gear assembly F Account for all washers shaft bushing and the gear CC668 3 Remove the shift shaft H then remove...

Page 61: ...s then slide the crank balancer gear off the crank bal ancer Account for the key in the keyway CD826 8 Remove the crank balancer NOTE There is a flat spot on the crank balancer bearing flange to allow clearance past the crank shaft CD832B 9 Remove the snap ring securing the water pump driven gear shaft 10 Using a hydraulic press remove the crankshaft assembly NOTE Use a protective end cap to preve...

Page 62: ...o ceed to Correcting Backlash in this sub section 1 Install a new bearing A onto the secondary driven shaft B making sure the bearing locating groove is directed away from the driven gear splines MT011A 2 Using a suitable press install the driven gear C on the shaft until the gear firmly seats on the shoulder of the shaft MT011B 3 If installing the existing shaft start with the shims removed durin...

Page 63: ... is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart...

Page 64: ...rod and crankshaft journal CC289D 3 Acceptable gap range must be within specifications Measuring Crankshaft Runout 1 Place the crankshaft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the indicator contact at point 1 of the crank shaft ATV 1074 3 Zero the indicator and rotate the crankshaft slowly 4 Maximum runout must not exceed specifications NOTE Proceed t...

Page 65: ... GZ312 3 Remove the reverse driven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer then remove the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer CAUTION When disassembling the countershaft care must be taken to note the direction each major component dog gear faces If a major component is installed facing ...

Page 66: ...d thrust washer GZ316 Assembling 1 From the drive gear end install a thrust washer bushing and bearing then install the low driven gear and washer GZ317A GZ318 2 Install the low driven gear locking washer then install the inner reverse driven gear washer GZ319B Manual Table of Contents ...

Page 67: ...cure the reverse driven gear assembly with a snap ring GZ288A GZ314 5 Install the reverse driven gear dog onto the counter shaft and secure with a snap ring GZ313A GZ312 6 From the opposite end of the countershaft install the high low driven gear dog A thrust washer B bushing C bearing D high low driven gear E and spacer washer F GZ283B Manual Table of Contents ...

Page 68: ...eating the bearing is not possible the crankshaft can be installed using a crankshaft installing tool 3 Install the crank balancer CD832B NOTE It will be necessary to rotate the crank bal ancer until the counterweight is facing away from the crankshaft then rotate the crankshaft clock wise into the journal area to allow the crank bal ancer to be fully seated 4 Place the key into the crank balancer...

Page 69: ...Apply High Temp Sealant to the right side mating surface smoothing out any build up or bumps 2 Lightly oil all bearings and grease all shafts in the left side crankcase 3 Using a plastic mallet lightly tap the case halves together until cap screws can be installed 4 From the right side install the 8 mm cap screws then tighten only until snug NOTE During the tightening procedure rotate the shafts b...

Page 70: ...e with hose clamps and tighten securely 4 Secure the front and rear driveshafts to the engine flanges with the cap screws and tighten to 20 ft lb then connect the upper and lower coolant hoses and tighten the clamps securely 5 Place a new grafoil seal in the cylinder head and a new grafoil seal on the muffler end of the exhaust pipe and install the exhaust pipe Secure with two exhaust springs and ...

Page 71: ... and spark plug cap HDX135A HDX137A 11 Install the throttle body into the intake manifold boot and secure with the clamp Tighten to 30 in lb 12 Install the air filter assembly and secure to the frame with four sheet metal screws then secure the intake boot with the clamp and tighten securely HDX148A 13 Connect the IAT sensor connector to the IAT sen sor and the crankcase breather tube to the crank...

Page 72: ... the cool ant bleed screw to allow trapped air to escape When clear coolant flows tighten the bleed screw HDX158B 17 Connect the negative battery cable to the battery and install the battery cover 18 Install the center skid plate center floorboard and seat base then install the seat back and seat 19 Start the engine and check for leaks allowing to warm up for several minutes then shut the engine o...

Page 73: ...Cooling 4 2 Electronic Fuel Injection 4 2 Gas Tank 4 3 Gas Vent Hoses 4 5 Oil Filter Oil Pump 4 5 Oil Cooler 4 6 Liquid Cooling System 4 6 Radiator 4 7 Thermostat 4 8 Fan 4 9 Water Pump 4 9 Electric Fuel Pump Fuel Level Sensor 4 10 Troubleshooting 4 12 Manual Table of Contents ...

Page 74: ...he engine over at normal speed 5 Check the air filter housing and air filter for contam ination Clean or replace as necessary see Section 2 REMOVING THROTTLE BODY 1 Turn the ignition switch to the OFF position then remove the ignition switch key 2 Remove the seat seat back and seat base then dis connect the battery 3 Remove the air inlet boot between the air filter and throttle body then disconnec...

Page 75: ...at seat back and seat base then remove the floor 2 Disconnect the vent hose A gasline hose B and fuel pump fuel level sensor connector C then cap the vent fitting and gas hose fitting PR698A 3 Remove the outer cap screw securing the front tank hold down then swing the hold down to the left PR167A PR170 4 Remove four press nuts securing the gas cap inset then remove the gas cap and inset Install th...

Page 76: ...el sensor for proper operation see Fuel Level Sensor in this section INSTALLING 1 Place the gas tank into position in the vehicle then install the inside rear hold down strap PR173 PR699A 2 Swing the front hold down to the right into position and install the cap screw and nut Do not tighten at this time PR171 3 Install the rear hold down strap joining cap screw and nut Do not tighten at this time ...

Page 77: ...cycling for this test 1 Remove the seat seat back and seat base 2 Using a suitable T fitting connect Oil Pressure Test Kit to the oil fitting and hose Tighten all clamps securely NOTE Some oil seepage may occur when install ing the oil pressure gauge Wipe up oil residue with a cloth 3 Block the wheels place the transmission in neutral and start the engine Allow the engine to warm up to operating t...

Page 78: ... the oil cooler PR484B CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Prior to washing inspect the oil cooler for signs of leaks such as oily dirt build up 2 Wash the cooling fins using a garden hose and hot soapy water and a soft brush 3 Inspect all mounting brackets and the oil inlet and outlet for cracks or bends INSTALL...

Page 79: ...wo shoulder bolts and nuts securing the radiator to the frame then disconnect the upper and lower coolant hoses PR184A 6 Lift the radiator assembly from the vehicle Account for two upper and two lower rubber mounting grom mets 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 contami...

Page 80: ...o cap screws securing the thermostat housing to the cylinder head Account for a thermo stat with seal INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the thermo stat for proper operation A Suspend the thermostat in a container filled with w...

Page 81: ...t If the pump is defective or if the mechani cal seal is leaking coolant dripping from the discharge hole the water pump must be replaced REMOVING 1 Remove the radiator cap then remove the water pump coolant drain plug and drain the coolant PR122A 2 Drain the oil from the engine transmission 3 Remove the seats and center console then remove the right side seat base 4 Loosen the coolant hose clamps...

Page 82: ...n switch ON and listen for a momen tary whirring sound of the pump building pressure If the sound is heard 10 seconds no electrical checks are necessary Turn the ignition switch OFF 2 Disconnect the gasline hose from the fuel rail then install a suitable pressure gauge FI092A 3 Turn the ignition switch to the ON position The fuel pressure should build until the pump shuts off Pres sure should read...

Page 83: ...per and resistor with clean alcohol and retest If still not correct replace the fuel level sensor 4 To replace the fuel level sensor use the following procedure A Disconnect the two wire connector A then press the fuel level sensor toward the top of the fuel pump to release it from the mounting slot B FI460A B Engage the tabs C of the fuel level sensor into the mounting slot B and press toward the...

Page 84: ...inated 1 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 TPS out of adjustment 1 Adjust TPS Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 1 Decrease RPM speed Manual Table of Contents ...

Page 85: ...5 Ignition Coil 5 6 EFI Sensors Components 5 6 Speed Sensor 5 7 Electronic Power Steering EPS 5 7 Ignition Switch 5 9 Headlight Switch 5 9 Drive Select Switch 5 9 Reverse Override Switch 5 10 Front Drive Actuator 5 10 Stator Coil Crankshaft Position CKP Sensor 5 11 Starter Motor 5 11 Starter Relay 5 12 Electronic Control Unit ECU 5 12 Regulator Rectifier 5 13 Headlights 5 13 Taillight Brakelight 5...

Page 86: ...point if the meter reads as speci fied the battery may be returned to service see step 10 7 If the meter reads less than specified voltage charge the battery using the following guidelines A When using an automatic battery charger always follow the charger manufacturer s instructions B When using a constant current battery charger use the following Battery Charging Chart Description p n Fluke Mode...

Page 87: ...is used readings may vary due to internal circuitry When troubleshooting a specific component always verify first the fuse s are good the bulb s are good the connections are clean and tight the battery is fully charged and all appropriate switches are activated NOTE For absolute accuracy all tests should be made at room temperature of 68 F Switches Each time the vehicle is used switches should be ...

Page 88: ...n 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 pedal must be depressed for this test 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to one black wire then connect the black tester lead to th...

Page 89: ... the power distribution mod ule NOTE To remove a fuse compress the locking tabs on either side of the fuse case and lift out 2411 213 NOTE Make sure the fuses are returned to their proper position according to amperage Refer to the amperage listed under each fuse on the power distribution module 2 Set the meter selector to the DC Voltage position 3 Connect the black tester lead to ground 4 Using t...

Page 90: ...rom the coil NOTE The coil is located to the right of the engine and may be accessed from behind the right side seat with the cargo box raised 2 Connect the red tester lead to the orange wire and the black tester lead to the blue white wire 3 Turn the ignition switch to the ON position The meter must show battery voltage EFI Sensors Components CRANKSHAFT POSITION CKP SENSOR To test the CKP sensor ...

Page 91: ...the new speed sensor into the housing with new O ring lightly coated with multi purpose grease then secure the sensor with the Allen head cap screw threads coated with blue Loctite 242 Tighten securely CD071 Electronic Power Steering EPS The electronic power steering EPS system is an elec tro mechanical device that utilizes 12 volt DC power to drive a motor linked to the steering shaft to assist t...

Page 92: ...witched with any other 4 pin relay on PDM replace relay if EPS normal after switching 3 Disconnect 2 pin connector on the EPS assembly and connect a volt meter set to DC voltage to the har ness black meter lead to BLK and red meter lead to ORG BRN With the ignition switch to the ON posi tion the meter must read more than 8 5 DC volts if correct voltage is not present check connections and wiring h...

Page 93: ...4 Connect the red meter lead to either of the two white wires then select the low beam position on the head light switch The meter must show battery voltage NOTE The battery voltage will show lower in steps 3 and 4 due to electrical loading of the headlights Drive Select Switch RESISTANCE 1 Remove the switch assembly from the dash then dis connect the harness from the switch NOTE The switch can be...

Page 94: ...oved to 2WD and 4WD Test the switch 30 amp fuse and wiring connections prior to test ing the actuator NOTE The differential must be in the unlocked position for this procedure VOLTAGE 1 Locate the 4 wire connector for the front drive selec tor actuator on the frame to the right of the differen tial then connect the red meter lead to the orange wire using a MaxiClip PR293 2 Connect the black lead t...

Page 95: ... wire then con nect the black tester lead to the green wire The meter reading must be within specification AC VOLTAGE NOTE The battery must be at full charge for these tests Crankshaft Position Sensor 1 Set the meter selector to the AC Voltage position 2 Connect the red tester lead to the blue wire then con nect the black tester lead to the green wire 3 Crank the engine over using the electric sta...

Page 96: ...ol lows 2 Connect the red tester lead to the positive battery ter minal then connect the black tester lead to the starter cable connection on the starter relay The meter must show battery voltage PR296 NOTE Make sure the ignition switch is in the ON position transmission in neutral and parking brake set 3 Depress the starter button while observing the multi meter The multimeter should drop to 0 vo...

Page 97: ...k tester lead to the black wire using a MaxiClip 3 Connect the red tester lead to the yellow wire high beam or white wire low beam using a MaxiClip The meter must show battery voltage NOTE If battery voltage is not shown in any test inspect the LIGHTS fuse on the power distribution module headlight switch ignition switch switch connectors or wiring harness Taillight Brakelight VOLTAGE Taillight NO...

Page 98: ...r 16 Speed Sensor 21 IAT Inlet Air Temperature Sensor 23 Tilt Sensor 24 Ignition Coil 1 26 Ignition Coil 2 H2 32 Fuel Injector 1 34 Fuel Injector 2 H2 40 ISC Idle Speed Control Valve 41 Fuel Pump Relay 60 Cooling Fan Relay 95 Sensor Power 96 Incorrect ECU 97 ECU Memory Power constant battery power 98 ECU to Gauge Comm Link H2 99 Start Run Not Possible active code only Will initiate code 99 After a...

Page 99: ...nect the three wire plug to the sensor then remove the right side mounting screw securing the sensor to the rear frame CD707 2 Install the needle adapters to the multimeter leads then select DC Voltage on the multimeter 3 Connect the red tester lead to the blue brown wire B and the black tester lead to the black yellow wire A then turn the ignition switch ON and observe the meter The meter should ...

Page 100: ... form the following resistance tests on the TPS PR535A NOTE If any meter reading is not as specified replace or adjust the TPS see INSTALL ING ADJUSTING in this sub section 7 Connect the main harness TPS connector to the TPS then using MaxiClips connect the black tester lead to the black wire and the red tester lead to the green black wire PR546A 8 Select the DC Voltage position on the meter and t...

Page 101: ...nstall the Test Plug from Test Plug Error Code List onto the plug 4 Turn the ignition switch to the ON position and note the position of the TPS indicator icon A B or C then adjust the TPS until the TPS icon appears in the center position B PR542A PR540A PR541A 5 Tighten the mounting screws securely then verify the TPS icon appears in the center position 6 Cycle the accelerator pedal to approximat...

Page 102: ...tator coils shorted grounded open 3 Regulator rectifier shorted punctured 1 Repair replace tighten lead wires 2 Replace stator coils 3 Replace regulator rectifier Problem Battery charges but charging rate is below the specification Condition Remedy 1 Lead wires shorted open loose at terminals 2 Stator coils grounded open 3 Regulator rectifier defective 4 Electrolyte low 5 Cell plates battery defec...

Page 103: ...high 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 high 3 Charging system charging operation not set prop erly 4 Cell plates overcharged damaged 5 B...

Page 104: ...5 20 NOTES Manual Table of Contents ...

Page 105: ...EM TABLE OF CONTENTS Drive System 6 2 Front Drive Actuator 6 2 Front Differential 6 3 Drive Axles 6 15 Rear Gear Case 6 20 Hub 6 22 Hydraulic Brake Caliper 6 24 Universal Joints 6 28 Troubleshooting 6 30 Manual Table of Contents ...

Page 106: ...e ignition switch is in the ON position The front drive actuator is located on the right 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 Sec tion 5 If the actuator runs constantly or makes squealing or grinding sounds the act...

Page 107: ...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 REMOVING 1 Remove the belly panel then place the vehicle on jack stands adjusted high enough to allow working from the underside of the vehicle NOTE The jack stands should be placed under the ...

Page 108: ...o drop or hang 11 Remove the lower shock cap screws Account for the lock nuts then move the shocks and upper A arm up and secure them with a strap PR200 12 Push the axle shaft toward the differential to release the plunge coupler then remove the axle from the differential Repeat for the opposite side PR729B 13 Remove the lower differential mounting cap screw Account for a lock nut and four washers...

Page 109: ...rear gear case 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 assem bling purposes GC015 CD106 3 Remove the snap rings from the input shaft then remove the input shaft from the pinion housing GC009A 4 Using a seal removal...

Page 110: ...eal making sure it is fully seated in the edge of the housing GC014 3 Lubricate the input shaft with High Performance 2 Molybdenum Disulphide Grease packing the boot ribs and splines then assemble allowing excess grease to freely escape Slight pressure on the boot will be present during assembly Secure with new clamps NOTE Any time drive splines are separated clean all splines with parts cleaning ...

Page 111: ...ion housing Account for the coupler fork and spring differential only GC015 2 Using a T 40 torx wrench remove the cap screws securing the differential cover Account for and make note of the ID tag location for assembling purposes GC003 3 Using a plastic mallet tap lightly to remove the dif ferential cover Account for an O ring KX174 NOTE If the cover is difficult to remove pry on the cover in more...

Page 112: ...side KX179 KX181 Disassembling Pinion Gear NOTE Any service of the pinion gear or related bearings will require a new gear case differential housing The removal of the lock collar severely damages the threads in the housing 1 Using the 48 mm Internal Hex Socket remove the lock collar securing the pinion gear assembly CC875 CC876 2 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pi...

Page 113: ...ing using a press CC884 3 Coat a new needle bearing and the bearing pocket of a new gear case differential housing with red Loctite 271 then using a suitable driver install the bearing lightly seated against the bearing seats Do not push the bearing too far into the pocket GC044 4 Install the pinion gear assembly into the housing Using the 48 mm Internal Hex Socket secure the pinion gear assembly ...

Page 114: ...et backlash prior to any other shimming 1 Install the existing shim or a 0 051 0 055 in shim on the gear case side of the ring gear assembly GC031A 2 Install the ring gear with shim in the gear case then while holding the pinion stationary rock the ring gear forward and back to determine if any backlash exists If no backlash exists install a thicker shim and recheck GC036A 3 Install the bearing fl...

Page 115: ...the pinion stationary rock the ring gear assembly forward and back and record the backlash Backlash must be 011 015 in If backlash is within specifications pro ceed to Ring Gear End Play If backlash is not within specifications increase shim thickness to increase backlash or decrease shim thickness to decrease backlash NOTE Higher backlash settings usually result in quieter gear operation GC037A R...

Page 116: ... gear case side of the ring gear with the chamfered side toward the ring gear then install into gear case differential housing GC031A GC020 2 Place the selected end play shim chamfered side toward the gear onto the cover side of the ring gear GC036B NOTE The spider and ring gear assembly must be replaced as a complete unit 3 Assemble the fork and sliding collar into the cover assembly then install...

Page 117: ...ft fork assembly making sure the fork leg is facing upward Apply a small amount of oil to the gasket then install the gasket CC893 8 Place the input shaft assembly onto the gear case housing then secure with the existing cap screws Tighten to 23 ft lb NOTE If a new housing is being installed tighten the cap screws to 28 ft lb CD103 CD110 Removing Installing Axle Seal NOTE This procedure can be per...

Page 118: ...ant into the differential and install the fill plug Tighten to 16 ft lb 5 Align the scribed match marks on the front input drive flange and the front drive yoke flange then secure with the cap screws tightened to 20 ft lb PR198A 6 Install the front axles 7 Install the knuckle assemblies onto the axles and ball joints then secure with four cap screws taking care not to damage the threads when insta...

Page 119: ...heels and tighten to 80 ft lb 13 Remove the vehicle from the support stand 14 Install the belly panel Drive Axles REMOVING REAR DRIVE AXLE 1 Secure the vehicle on a support stand to elevate the wheels 2 Place the transmission in park then remove the wheels 3 Remove the cotter pins securing the axle nuts then remove the nuts KX041 4 Slide the hub out of the knuckle and set aside PR221 5 Remove the ...

Page 120: ...ponents to determine if any service or replace ment is necessary 1 Using a clean towel wipe away any oil or grease from the axle components CD019 2 Inspect boots for any tears cracks or deterioration NOTE If a boot is damaged in any way it must be replaced with a boot kit DISASSEMBLING AXLES 1 Using a side cutters or suitable substitute remove the large clamp from the boot CD020 2 Wipe away excess...

Page 121: ...e position of the different sized clamps for assembling purposes CD751 8 Apply 40 grams 1 3 of contents of grease from the grease pack included in Front Axle Boot Repair Kit into the knuckles and the new outside boot ATV 1052 NOTE The grease pack contains 120 grams of grease The inside joint double offset requires approximately 70 90 grams of grease and the out side bell type requires approximatel...

Page 122: ...sing 4 Install the bearing onto the shaft making sure the recess of the bearing is facing the housing CD022 5 Secure the bearing ring with the snap ring making sure the sharp side of the snap ring faces away from the boot CD023 6 Making sure the marks made during disassembling align slide the housing over the bearing ring then completely seat the bearing ring into the housing and install the snap ...

Page 123: ...e 4 Tighten the hub hex nut from step 3 to 200 ft lb then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut CD027 5 Install the wheel Tighten to 80 ft lb 6 Remove the vehicle from the support stand and release the parking brake INSTALLING FRONT DRIVE AXLE 1 Push the axle shaft into the CV coupler to release the lock ring then position the drive axle in th...

Page 124: ...e then remove the gear case through the upper left side of the frame and lift out the top PR207 RING GEAR THRUST BUTTON Removing 1 Remove the cap screws securing the gear case cover to the gear case then remove the ring gear 2 Remove the thrust button from the gear case cover left hand threads Account for a shim Inspecting 1 Inspect the ring gear for excessive wear missing or chipped teeth or disc...

Page 125: ... SHAFT HOUSING Removing Disassembling 1 Remove the cap screws securing the rear drive input shaft housing to the rear gear case then remove the input housing assembly GZ183 2 Remove the input shaft from the input housing then remove the oil seal GZ180 GZ182A 3 Remove the snap ring retaining the input bearing and using an appropriate bearing driver press the bearing from the housing GZ184A Cleaning...

Page 126: ...al to the frame with two through bolts and secure with lock nuts and flat washers Tighten to 38 ft lb 4 Install the rear drive axles see Drive Axles in this section 5 Install the brake caliper and tighten the mounting cap screws to 20 ft lb 6 Fill the gear case with the appropriate lubricant Hub REMOVING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel NOTE Removi...

Page 127: ...REPLACING WHEEL STUDS 1 Secure the hub in a suitable holding fixture and remove the brake disc if applicable 2 Drive the damaged stud out of the hub then place the new stud into the hub and thread on an appropriate flange nut PR250 3 Using a socket and ratchet handle tighten the nut until the stud is fully drawn into the hub PR252A INSTALLING 1 Secure the brake disc if applicable to the hub with t...

Page 128: ...luid is exposed to air drain all fluid and replace with new DOT 4 brake fluid from an unopened con tainer Brake fluid readily absorbs moisture from the air significantly lowering the boiling point This increases the chance of vapor lock reducing braking power and increasing stopping distance 3 Remove the brake hose from the caliper and close the bleed screw then remove the caliper WARNING Arctic C...

Page 129: ... noting the location of the different sized O rings Dis card all seals O rings and crush washers CLEANING AND INSPECTING 1 Clean all caliper components except the brake pads with DOT 4 brake fluid Do not wipe dry 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Section 2 3 Inspect the brake caliper housings for scoring in the piston bores chipped seal ring g...

Page 130: ...er making sure the caliper and holder are correctly oriented NOTE It is very important to apply silicone grease to the O rings and caliper bores prior to assembly PR239C 5 Making sure brake fluid does not contact the brake pads compress the caliper holder toward the caliper and install the inner brake pad then install the outer pad PR238 CAUTION If brake pads become contaminated with brake fluid t...

Page 131: ...s to the master cylinder then remove the master cylinder Discard the three crush washers Inspecting 1 Inspect the master cylinder push rod and clevis for wear bending or elongation of clevis holes 2 Inspect the push rod boot for tears or deterioration 3 Inspect the reservoir for cracks and leakage 4 Inspect the brake hose for cracks and deterioration and the condition of the banjo fittings Install...

Page 132: ...ve the bearing cup retainers 5 Using a suitable socket and ratchet handle rotate the jackscrew to push the bearing cup out of the yoke then remove the tool and the bearing cup PR359 6 Install the separator tool on the opposite side of the yoke to push the second bearing cup from the yoke then remove the tool and separate the universal joint 7 Secure the separator tool in a vise and repeat steps 4 ...

Page 133: ...s 2 3 for the opposite side bearing cup 4 Remove the separator tool from the vise and install the universal joint bearing cups and movable yoke into the fixed yoke using the same procedure as steps 2 3 except the vise cannot be used PR355 5 Check that the universal joint can be flexed freely without binding then apply multi purpose grease to the splines and install the driveshaft noting the match ...

Page 134: ...riven 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 Front drive actuator not operating 1 Replace gear s 2 Replace shaft 3 Replace coupling 4 Replace joint 5 Replace gear s 6 Replace gears pinions 7 Replace fuse drive select switc...

Page 135: ...7 1 7 SECTION 7 SUSPENSION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 3 Rear A Arms 7 5 Wheels and Tires 7 6 Troubleshooting 7 8 Manual Table of Contents ...

Page 136: ...ch AF626D 4 Using a suitable spring compression stand compress the shock absorber spring remove the retainer and remove the spring AF730D CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all shock absorber components in parts clean ing solvent 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect...

Page 137: ... Remove the cotter pin and slotted nut securing the tie rod end to the knuckle then remove the tie rod end from the knuckle 7 Remove the cap screws securing the ball joints to the knuckle PR193 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 AF626D 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remo...

Page 138: ...Install the ball joint into the A arm and secure with the snap ring AF616D 2 Install the A arm assemblies into the frame mounts and secure with the cap screws Only finger tighten at this time AF610D 3 Route the brake hose through the upper A arm shock absorber mount AF627D 4 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut to 33 ft lb 5 Secure the A arm assemblies to th...

Page 139: ...operly aligned PR260 13 Install the wheel and tighten to 80 ft lb 14 Remove the vehicle from the support stand Rear A Arms REMOVING 1 Secure the vehicle on a support stand to elevate the wheels 2 Place the transmission in park 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut 5 Remove the cap screws and lock nut securing the shock absorber to the frame and low...

Page 140: ...ecure the nut NOTE If the cotter pin can not be inserted due to misalignment of the hole in the axle and the slots in the nut tighten the nut until properly aligned PR196 7 Secure the shock absorber to the frame with a cap screw and new lock nut Tighten to 33 ft lb 8 Secure the shock absorber to the lower A arm with a cap screw and new lock nut Tighten to 20 ft lb 9 Secure the boot guard to the lo...

Page 141: ...ach wheel on its hub and secure with the exist ing hardware 2 Tighten to 80 ft lb CHECKING INFLATING 1 Using an air pressure gauge measure the air pressure in each tire Adjust the air pressure as necessary to meet the recommended inflation pressure 2 Inspect the tires for damage wear or punctures NOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and ...

Page 142: ...1 Adjust preload 2 Replace bushing Problem Suspension noisy Condition Remedy 1 Cap screws suspension system loose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Vehicle pulling or steering erratic Condition Remedy 1 Vehicle steering is erratic on dry level surface 2 Vehicle pulls left or right on dry level surface 1 Check front wheel alignment and adjust if necessary...

Page 143: ...6 Upper Steering Shaft 8 6 Intermediate Steering Shaft Assembly 8 7 Steering Knuckles 8 8 Checking Adjusting Front Wheel Alignment 8 10 Front Bumper Assembly 8 11 Hood 8 11 Fenders 8 12 Floor 8 12 Dashboard 8 13 Belly Panel 8 13 Exhaust System 8 13 Cargo Box 8 14 Taillight Assembly 8 14 Seat 8 15 Troubleshooting 8 15 Manual Table of Contents ...

Page 144: ...ubleshoot the EPS system prior to replacing the EPS assembly see Section 5 as there are several possible external causes for system failure 1 Support the vehicle on appropriate stands or a lift then remove the left front wheel and left front shock absorber 2 Remove the front storage box then disconnect the two electrical connectors from the EPS assembly PR759A 3 Remove the cap screw securing the i...

Page 145: ... until the EPS is engaged with the coupler 3 Install the EPS assembly into the coupler turning the EPS shaft slightly to align the index spline then seat the EPS firmly onto the frame 4 Install four cap screws securing the EPS assembly to the frame and tighten to 35 ft lb 5 Install the cap screw in the EPS to rack coupler and tighten to 11 ft lb 6 Connect the two electrical connectors then align t...

Page 146: ...s section 2 Support the steering rack assembly in a suitable holding fixture or bench vise then cut the securing band and slide the boot toward the outer tie rod end 3 Using a punch or chisel bend the lock washer away from the flats on the tie rod joint PR780 4 Using an appropriate crow foot and backing wrench remove the tie rod assembly NOTE Tie rods come as a complete assembly No further disasse...

Page 147: ...t then remove the cap screws securing the steering rack assembly to the rack bracket and remove from the left side INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the tie rod ends for damaged threads torn boots or excessive wear 2 Inspect the tie rods for bends or deformation 3 Inspect the rack and pinion to tie rod boots for tea...

Page 148: ...e nut securing the steering wheel and remove the steering wheel INSPECTING 1 Inspect the steering wheel for cracks missing pad ding or broken spokes 2 Inspect the splines for wear 3 Check that the steering wheel is not bent INSTALLING 1 Install the steering wheel aligning the two match marks then apply a drop of red Loctite 271 to the threads of the nut and secure the steering wheel Tighten to 25 ...

Page 149: ... cap screws and nuts Tighten the 6 mm nuts to 8 ft lb and the 8 mm nuts to 20 ft lb PR764B 3 Install the cap screw in the intermediate shaft coupler and tighten to 31 ft lb PR765A Intermediate Steering Shaft Assembly REMOVING With the upper steering shaft removed remove the cap screw from the intermediate shaft coupler and remove the shaft from the EPS and vehicle INSPECTING NOTE The lower steerin...

Page 150: ...AND DISASSEMBLING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel 2 Remove the cotter pin from the axle 3 Remove the nut securing the hub 4 Remove the brake 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 PR193 8 Tap the b...

Page 151: ...octite 271 Tighten to 30 ft lb then install a new cotter pin and spread the pin NOTE During assembling new cotter pins should be installed 4 Apply a small amount of grease to the hub splines PR290A 5 Install the hub assembly onto the splines of the shaft CD009 6 Secure the hub assembly with the nut Tighten to 200 ft lb PR256 7 Install a new cotter pin and secure by spreading as shown Manual Table ...

Page 152: ...res at the front and rear of the tire then using a tape measure measure and record the distance between the marks at the front and rear The front measurement should be 6 12 mm 1 4 1 2 in greater than the rear measurement toe out PR087A To adjust the wheel alignment use the following proce dure 1 Center the steering wheel then using an open end wrench to hold the tie rod ends loosen the right side ...

Page 153: ...four headlight connectors and remove two nylon ties PR328A 2 Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame then lower the hood PR332A 3 Finish removing the cap screws and flange nuts from step 2 then remove the hood assembly CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 C...

Page 154: ...ace the appropriate fender into position and secure with existing hardware Floor REMOVING 1 Remove the seat seat back and seat base 2 Remove the self tapping screws securing the side foot restraints 3 Remove the center floorboard HDX132A 4 While pulling forward on the upper rear of the floor lift the rear part of the floor above the seat locating stud PR163 PR164 NOTE To aid in removing insert a s...

Page 155: ...s and park seat belt indicator light connector and remove the dash assembly 5 Slide the dash assembly rearward and off the steer ing shaft and shift lever assemblies INSTALLING 1 Place the dash into position and connect the park seat belt indicator light dash harness and gauge connector 2 Secure the dash with the six sheet metal and three machine screws Do not over tighten 3 Install the steering s...

Page 156: ...count for four pivot housings CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all cargo box components with soap and water 2 Inspect the cargo box for cracks tears and loose hardware 3 Inspect the welds of the cargo box frame for cracking or bending 4 Inspect the cargo box gate latches for smooth opera tion INSTALLING ...

Page 157: ...tion pressure incorrect 4 Tie rod ends seizing 5 Linkage connections seizing 1 Adjust alignment 2 Lubricate appropriate components 3 Adjust pressure 4 Replace tie rod ends 5 Repair replace connections Problem Steering oscillation Condition Remedy 1 Tires inflated unequally 2 Wheel s wobbly 3 Wheel hub cap screw s loose missing 4 Wheel hub bearing worn damaged 5 Tie rod ends worn loose 6 Tires defe...

Page 158: ...bearings 3 Lubricate appropriate components 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 Parking brake adjusted incorrectly 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 1 Replace bearings 2 Replace tires 3 Replace rim 4...

Page 159: ...9 1 9 SECTION 9 CONTROLS INDICATORS TABLE OF CONTENTS Accelerator Pedal 9 2 Shift Lever 9 2 Shift Cable 9 2 Speedometer Tachometer LCD Indicator Lights 9 3 Manual Table of Contents ...

Page 160: ...uator arm Shift Lever REMOVING 1 Remove the dashboard see Dashboard in Section 8 2 Remove the nut securing the shift cable to the shift arm then remove the four cap screws securing the shift axle supports to the frame and remove the shift lever HDX166A HDX168A INSTALLING 1 Install the shift axle supports onto the shift lever then secure the axle supports to the frame with four cap screws and tight...

Page 161: ...t the cable end to the shift arm and secure with the E clip 3 Install the shift cable into the shift cable support then connect the shift cable end to the shifter and secure with a cap screw and nut Tighten to 8 ft lb 4 Adjust the shift cable see Shift Lever Adjusting Shift Cable in section 2 5 Install nylon ties on the shift cable where removed then install the center floorboard and tighten the m...

Page 162: ...e the gauge holder over the mounting screws and secure with the nuts 7 Plug the multi pin connector into the gauge then turn the ignition switch to the ON position and check gauge functions 8 Slide the dash into position and secure with the six screws 9 Install the shifter handle then install the steering boot support PR762A 10 Install the steering boot onto the boot support 11 Install the steerin...

Page 163: ... Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2258 933 ...

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