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Arctic Cat 2012 350 HS, Service Manual

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Arctic Cat 2012 350 HS Service Manual Download Page 28

27

KC235

KC236

6. Remove the cap screws securing the exhaust pipe to

the cylinder head; then disconnect the exhaust pipe

to muffler springs and remove the exhaust pipe.

Account for a grafoil seal and seal ring.

KC170

KC238

7. Disconnect the gear position switch, starter cable,

and engine ground cable; then disconnect the trigger

coil and stator coil connectors.

KC228C

KC228B

8. Remove the front and rear V-belt cooling boots from

the V-belt housing.

9. Remove the cap screws from the front and rear out-

put flanges; then remove the front and rear engine

mounting through-bolts.

KC242

KC243

Manual

Table of Contents

Summary of Contents for 2012 350 HS

Page 1: ...oint to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death 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 ...

Page 2: ...enter Crankcase Components 53 Separating Crankcase Halves 53 Disassembling Crankcase Half 54 Servicing Center Crankcase Components 55 Assembling Crankcase Half 60 Joining Crankcase Halves 62 Installing Engine Transmission 63 Fuel Lubrication Cooling 67 Electric Choke 67 Carburetor 67 Throttle Cable Free Play 73 Engine RPM Idle 73 Gas Tank 73 Oil Filter Oil Pump 75 Testing Oil Pump Pressure 75 Oil ...

Page 3: ...k Generator Output approx 220W 5000 RPM CRANKSHAFT Connecting Rod small end max 20 021 mm Connecting Rod big end side to side max 0 7 mm Connecting Rod big end width 21 95 22 00 mm Connecting Rod small end deflection max 3 0 mm Crankshaft web to web 60 9 mm Crankshaft Runout max 0 03 mm CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 060 0 073 mm Piston Diameter 15 mm from Skirt End 80...

Page 4: ...ng Engine 8 11 Starter One Way Clutch Flywheel 26 35 Oil Pump Crankcase 8 11 Movable Drive Face Nut Clutch Shaft 147 199 Oil Cooler Hose Clamps Engine Oil Cooler 30 in lb 3 4 Valve Inspection Cover Cylinder Head Cover 8 11 STEERING COMPONENTS Steering Post Bearing Housing Frame 20 27 Handlebar Cap Steering Post 20 27 Lower Steering Post Bearing Cap Screw Steering Post 40 54 Tie Rod End Steering Po...

Page 5: ... 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 of moisture in the fuel system RECOMMENDED ENGINE TRANSMISSION OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil which has been specifically formulated for use in this Arctic Cat engine Althoug...

Page 6: ...ject the preserver into the air filter opening for a period of 10 to 20 seconds Stop the engine Install the air filter and housing cover NOTE At this point drain the carburetor float chamber 4 Plug the exhaust outlet on the muffler with a clean cloth 5 Apply light oil to the upper steering post bushing and plungers of the shock absorbers 6 Tighten all nuts bolts cap screws and screws Make sure riv...

Page 7: ...y cables 6 Check the entire brake systems fluid level pads etc all controls lights and headlight aim adjust or replace as necessary 7 Tighten all nuts bolts cap screws and screws mak ing sure all calibrated nuts cap screws and bolts are tightened to specifications 8 Check tire pressure Inflate to recommended pressure as necessary 9 Make sure the steering moves freely and does not bind 10 Check the...

Page 8: ...4 178 Item Initial Service After Break In First Mo or 100 Mi Every Day EveryMonthor 100 Miles Every 3 Months or 300 Miles Every 6 Months or 500 Miles Every Year or 1500 Miles As Needed Battery I I C Fuses I R Air Filter Drain Tube I I C R Valve Tappet Clearance I I A Engine Compression I Spark Plug I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R GasVent Hoses I I R 2 Yrs Throttle Cable I I C L A...

Page 9: ...e ment in the solvent and wash it NOTE Foam Air Filter Cleaner and Foam Air 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 oil into the element Insert the form ing spring into the element with the closely wrapped end of the spring toward the open end of the element 6 Clean any dirt or debris from inside the air...

Page 10: ...icing Top Side Components CF005 2 Rotate the crankshaft to the TDC position on the compression stroke NOTE At this point the rocker arms and adjuster screws must not have pressure on them Feeler Gauge Procedure Using a feeler gauge check each valve tappet clearance If clearance is not within specifications loosen the jam nut and rotate the tappet adjuster screw until the clear ance is within speci...

Page 11: ...low any debris from around the spark plug 3 Remove the spark plug then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole 4 Attach the Compression Tester Kit NOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the throttle lever in the full open posi tion crank the engine over with the el...

Page 12: ...emove the arrester KC334A 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 spark arrester assembly with gasket then secure with the cap screws Tighten to 48 in lb KC145 Adjusting Throttle Cable To adjust the throttle cable free play follow this proce dure 1 Sl...

Page 13: ...o a new filter seal ring and check to make sure it is positioned correctly then install the new oil filter Tighten securely 8 Install the engine drain plug and tighten to 20 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug 9 Start the engine while the ATV is outside on level ground and allow it to idle for a few minutes 10 Turn the e...

Page 14: ...en drained install the drain plugs and tighten to 45 in lb 4 Pour the appropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole 5 Install the fill plugs and tighten to 16 ft lb NOTE If the differential rear drive oil is contami nated with water inspect the drain plug filler plug and or bladder Tires TIRE SIZES The ATV is equipped with low pressure tubeless tires of the s...

Page 15: ...et may be bent or damaged or the CDI unit may be faulty Lights Rotate the ignition switch to the lights position the head lights and taillights should illuminate Test the brake lights by compressing the brake lever The brakelights should illuminate HEADLIGHTS NOTE The bulb portion of a headlight is fragile HANDLE WITH CARE When replacing a headlight bulb do not touch the glass portion of the bulb ...

Page 16: ... To replace the bulbs use the following procedure 1 Rotate the bulb socket counterclockwise to release from light housing then press in on the bulb and turn counterclockwise to release from the socket KC158A 2 Install a new bulb and press in rotating clockwise to secure then place the socket into the light housing and turn clockwise to secure KC158B CHECKING ADJUSTING HEADLIGHT AIM The headlights ...

Page 17: ...ctions but the shift lever does not corre spond with the gear indicated on the LCD adjust the shift linkage To adjust proceed to ADJUSTING ADJUSTING 1 Remove the seat then remove the left side engine cover 2 With the ignition switch in the ON position loosen jam nut A left hand threads then loosen jam nut C and with the shift lever in the reverse position adjust the coupler B until the transmissio...

Page 18: ... this point perform step B C and D on the other FRONT bleeder screw then move to the REAR bleeder screw and follow the same proce dure 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...

Page 19: ...nough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate to 0 5 mph 3 Repeat procedure on each brake system twenty times 4 Adjust the auxiliary brake if necessary 5 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed Checking Replacing V Belt R...

Page 20: ...pproximately 3 4 in KC137 5 Pinching the V belt together in front of the driven pulley pull it forward and outward off the clutch shaft then remove it from the driven pulley KC136 6 Inspect the faces of the drive and driven pulleys for scoring pitting cracks or grooving then clean any dirt and debris from the V belt housing and cover INSTALLING 1 Place the V belt onto the driven pulley making sure...

Page 21: ...ove the cap screw from the fixed driven face then rotate the pulleys counterclockwise until the driven pulley faces are together 5 With the two alignment pins installed in the V belt housing and a new V belt cover gasket in place install the V belt cover Using the pattern shown secure with the cap screws tightened to 8 ft lb KC142A KC153A 6 Slide the auxiliary brake pedal fully onto the pivot stud...

Page 22: ...21 KC149A Manual Table of Contents ...

Page 23: ...kets lock nuts and seals and lubricating all internal components when servicing the engine transmis sion SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appro priate tool description NOTE Special tools are available from the Arctic Cat Service Parts Department Descript...

Page 24: ...reen 4 Replace valve Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Valve clearance out of adjustment 5 Carburetor jets obstructed 1 Clean plug 2 Replace stator coil 3 Replace CDI unit 4 Adjust clearance 5 Clean jets Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excessive 2 Valve spring s weak broken 3 ...

Page 25: ...arms tappets worn 5 Spark plug gap too narrow 6 Ignition coil defective 7 Float level too low 8 Air cleaner element obstructed 9 Fuel hose obstructed 1 Shift into higher gear decrease speed 2 Replace springs 3 Correct timing check chain sprockets and cam chain ten stioner 4 Replace cam arms tappets 5 Adjust gap 6 Replace ignition coil 7 Adjust float height 8 Clean element 9 Clean or replace hose P...

Page 26: ...il circuit obstructed 6 Intake manifold leaking air 7 Fan malfunctioning 8 Fan switch malfunctioning 9 Gasoline level in float chamber too low 1 Clean piston 2 Add oil 3 Drain replace gasoline 4 Replace pump 5 Clean circuit 6 Tighten replace manifold 7 Check fan fuse replace fan 8 Replace fan switch 9 Adjust float height Manual Table of Contents ...

Page 27: ...50 KC249 4 Disconnect the speedometer sensor then remove the E clip securing the shift rod to the shift arm and discon nect the shift rod Account for a bushing and flat washer KC248 KC255 5 Remove the inlet air duct air filter housing and air silencer duct then remove the carburetor and set aside leaving the throttle cable attached AT THIS POINT If the technician s objective is to service Top Side...

Page 28: ... ring KC170 KC238 7 Disconnect the gear position switch starter cable and engine ground cable then disconnect the trigger coil and stator coil connectors KC228C KC228B 8 Remove the front and rear V belt cooling boots from the V belt housing 9 Remove the cap screws from the front and rear out put flanges then remove the front and rear engine mounting through bolts KC242 KC243 Manual Table of Conten...

Page 29: ...shaft to top dead cen ter of the compression stroke NOTE Arctic Cat recommends the use of new gas kets lock nuts and seals and lubricating all internal components when servicing the engine transmis sion 1 Remove the cap screws securing the two valve inspection covers Remove the two covers Account for the O rings MD1264 NOTE Keep the mounting hardware with the covers for assembly purposes 2 Remove ...

Page 30: ...he C ring down into the crankcase 6 Noting the timing marks for installing purposes drop the sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cyl inder head Account for an alignment pin NOTE Loop the chain over the cylinder and secure it to keep it from falling into the crankcase MD1132 7 Remove the cam chain tensioner by lifting it from the chain ca...

Page 31: ...ift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase Account for the gasket and two alignment pins MD1214 13 Using an awl remove the piston pin circlips Take care not to drop them into the crankcase MD1213 14 Using Piston Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston AT THIS POINT To service valves and cylin...

Page 32: ...ts before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Keep all valves and valve components as a set Note the original location of each valve set for use during installation Return each valve set to its original location during installation 1 Using a valve spring compressor compress the valve ...

Page 33: ... of the valve face FI367 2 Acceptable width must be at or above specifications Measuring Valve Face Radial Runout 1 Mount a dial indicator on the surface plate then place the valve stem on a set of V blocks 2 Position the dial indicator contact point on the out side edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifica...

Page 34: ...uide CC144D 2 Insert each valve into its original valve location 3 Install the valve springs 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 an...

Page 35: ...pin outside diameter at each end and in the center If measurement exceeds specifica tions the piston pin must be replaced ATV 1070 2 Inspect and measure the connecting rod small end If the measurement exceeds specifications the con necting rod must be replaced see Center Crankcase Components in this section 3 Insert an inside dial indicator into the piston pin bore Take two measurements to ensure ...

Page 36: ...right 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 Measuring Cylinder Head Distortion 1 Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion between the head and the straightedge 3...

Page 37: ...oduce the proper 60 cross hatch pat tern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not available use a lightweight petroleum based oil Thoroughly clean cylinder after honing using soap and hot water Dry with compressed air then immediately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder CC390D 4 If any measuremen...

Page 38: ...ap screws securing the cylinder head cover to the cylinder then remove the cylinder head cover and camshaft MD1261 5 Match the width of the plasti gauge with the chart found on the plasti gauge packaging to determine camshaft to cylinder head and cylinder head cover clearance CC145D 6 If clearance is excessive measure the journals of the camshaft CC287D NOTE If the journals are worn replace the ca...

Page 39: ...ngers 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 MD1345 4 Loosely install the two nuts securing the cylinder to the right side crankcase half NOTE The two cylinder to crankcase nuts will be tightened in step 9 KC337A C Cylinder Head Camshaft D Cyl...

Page 40: ... ft lb Tighten the two lower cylinder head nuts from step 8 to 20 ft lb and the cylinder to crankcase nuts from step 4 to 8 ft lb 10 With the timing inspection plug removed and the cam chain held tight rotate the crankshaft until the piston is at top dead center 11 While holding the cam chain sprocket to the side install the rear cam chain tensioner guide into the cylinder head Install the pivot c...

Page 41: ... sure the cam lobes end up in the down position 15 When the camshaft assembly is seated ensure the following 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 1...

Page 42: ...ded lock and push the plunger into the tensioner MD1146 23 Place the cam chain tensioner assembly and gasket into the cylinder making sure the ratchet side is fac ing toward the top of the cylinder and secure with the two cap screws MD1254 24 Install the cap screw and spring into the end of the cam chain tensioner Tighten securely MD1245 25 Loosen the adjuster screw jam nuts then loosen the adjust...

Page 43: ...ve the cover 2 Remove the left side cover to crankcase mounting cap screws noting the location of the 8 mm cap screw with the washer near the middle of the left side cover Keep the different lengthed 6 mm cap screws in order for installing purposes MD1186 3 Using Crankcase Separator Crankcase Remover and the 6 mm adapter remove the left side cover w stator assembly Account for the two alignment pi...

Page 44: ... for the key MD1368 MD1369 MD1370 7 Remove the starter idler gear No 1 and starter idler gear No 2 MD1305 8 Remove the gear shift shaft assembly and washer from the left side crankcase Note the positions of the alignment marks and washer for installing pur poses then release the cam stopper spring tension MD1239 CAUTION Care must be taken that the remover is fully threaded onto the rotor flywheel ...

Page 45: ...ocks up both ways the starter clutch must be replaced 2 Inspect the starter clutch gear for chipped or missing teeth or discoloration scoring of the clutch surface Inspect the bearing for loose worn or discolored rollers If bearing is damaged it must be replaced FI569 3 Inspect the one way bearing for chipped surfaces missing rollers or discoloration If any of the above conditions exist replace th...

Page 46: ...ith the lower chamfer radius FI580 Installing Left Side Components A Starter Idler Gears B Rotor Flywheel 1 Place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three cap screws securely MD1122 2 Install the starter motor and tighten the two cap screws to 8 ft lb 3 Install the shift detent cam making sure the washer is properly p...

Page 47: ...d 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 Removing Right Side Components A V Belt Cover B Driven Pulley C Clutch Cover 1 If the engine is still in the frame remove the cap screw securing the brake pedal to the pivot shaft Account for a flat...

Page 48: ...034 MD1036 5 Remove the V belt MD1118 6 Remove the fixed drive face MD1094 7 Remove the nut holding the driven pulley assembly then remove the driven pulley assembly MD1068 8 Using an impact screwdriver remove the three Phil lips head cap screws holding the air intake plate Remove the air intake plate MD1092 Manual Table of Contents ...

Page 49: ...r G Oil Pump NOTE Steps 1 10 in the preceding sub section must precede this procedure KC324A KC326A 11 Remove the one way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes MD1286 12 Remove the left hand threaded nut holding the cen trifugal clutch assembly MD1014 MD1016 13 Remove the cam chain AT THIS POINT Remove the cap screw holding the gear position switc...

Page 50: ...screws holding the oil pump and remove the oil pump Account for two alignment pins MD1060 Servicing Right Side Components NOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary INSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoe for uneven wear chips cracks or discoloration AT THIS POINT To service clutch components see Servicing R...

Page 51: ... the clutch shoe can only be rotated coun terclockwise in respect to the clutch housing If the clutch shoe locks up or turns either direction the one way clutch must be replaced KC332A 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 NOTE The oil pump is a non serviceable compo nent and...

Page 52: ...tighten the cap screw coated with red Loc tite 271 to 63 ft lb MD1017 MD1018 5 Install the clutch shoe assembly on the crankshaft then install the flange nut left hand thread coated with red Loctite 271 Tighten to 147 ft lb NOTE The flat side of the flange nut should be directed towards the clutch shoe 6 Install the one way clutch making sure that the green dot or the word OUTSIDE is directed away...

Page 53: ... position Install the clutch cover MD1115 8 Tighten the clutch cover cap screws to 8 ft lb MD1117 9 Install the air intake plate Apply red Loctite 271 to the threads of the three Phillips head cap screws then install and tighten securely MD1342 10 Place the driven pulley assembly into position and secure with the nut threads coated with red Loctite 271 Tighten to 147 ft lb MD1068 KC134 Manual Tabl...

Page 54: ...nt the cap screw can be removed from the driven pulley face 15 Rotate the V belt and drive driven assemblies until the V belt is flush with the top of the driven pulley 16 Install two alignment pins and place a new V belt cover gasket into position on the clutch cover In a crisscross pattern tighten cap screws to 8 ft lb KC142A Center Crankcase Components NOTE This procedure cannot be done with th...

Page 55: ...hen separating the halves MD1313 Disassembling Crankcase Half 1 Remove the secondary and primary driveshaft assemblies Account for the bearing alignment C ring on the bearing boss next to the driven gear MD1317 NOTE Note the location of the bearing alignment pin on the secondary output shaft 2 Remove the reverse idler gear spacer and sleeve Account for the washer MD1325 3 Remove the driveshaft MD1...

Page 56: ...se using a rubber mallet drive out the output shaft assembly Account for the output shaft a shim a washer and the nut Servicing Center Crankcase Components NOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary SECONDARY GEARS NOTE When checking and correcting secondary gear backlash and tooth contact the output drive flange must be secured...

Page 57: ...thin tolerance Note the following chart Checking Tooth Contact NOTE After correcting backlash of the secondary driven bevel gear it is necessary to check tooth con tact 1 Remove the secondary driven output shaft assembly from the left side crankcase half 2 Clean the secondary driven bevel gear teeth of old oil and grease residue 3 Apply a thin even coat of a machinist layout dye to several teeth o...

Page 58: ...the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal CC289D 3 Acceptable gap range must be within specifications Measuring Connecting Rod Big End Width 1 Using a calipers measure the width of the connecting rod at the big end bearing 2 Acceptable width range must be within specifica tions Measuring Crankshaft Runout 1 Place the crankshaft ...

Page 59: ...er then remove the low driven gear along with the bearing and bushing FI666 FI667 4 Remove the splined washer then remove the circlip securing the high low sliding dog Remove the slid ing dog FI668 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 the wrong direction transmission damage ...

Page 60: ...countershaft install the high driven gear bushing 3 bearings 2 and gear 4 on the countershaft then install the washers 5 and secure with the snap ring FI671A FI670 2 Install the high low shift dog 6 on the countershaft and secure with snap ring 7 then install the splined washer 8 FI668A 3 Install the low driven bushing 10 bearing 9 and gear 11 on the countershaft then install splined washer 12 FI6...

Page 61: ...ow ready to be installed Assembling Crankcase Half NOTE For ease of assembly install components on the right side crankcase half NOTE If the output shaft was removed make sure that the proper shim is installed 1 Install the output shaft into the crankcase making sure the two gears shim washer and nut are in the correct order MD1199 MD1079 2 Apply red Loctite 271 to the threads of the output shaft ...

Page 62: ...n the crank balancer shaft then install the gear and aligning the timing marks slide the gear into place FI658 6 Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end install the shift shaft into the crankcase FI652A 7 Place the shift forks into position on the assembled countershaft and install into the crankcase as an assembly FI662 FI653 8 Align th...

Page 63: ...the two alignment pins are in place and that both case halves are clean and grease free Apply Three Bond Sealant to the mating surfaces Place the right side half onto the left side half MD1336 2 Using a plastic mallet lightly tap the case halves together until cap screws can be installed 3 From the right side install the crankcase cap screws noting the location of the different sized cap screws th...

Page 64: ...d forth to ensure no binding or sticking occurs Installing Engine Transmission 1 From the right side place the engine transmission into the frame tilting the top side forward to clear the frame member KC216 2 Install the front and rear engine mounting through bolts and secure with the flange nuts Tighten to 38 ft lb 3 Align the front and rear output flanges with the drive couplers then secure with...

Page 65: ...et the inlet air silencer into the frame then install the exhaust pipe using a new exhaust pipe seal and grafoil seal Tighten the cap screws evenly to 20 ft lb and install the muffler retainer springs KC237 KC238 KC170 7 Place the carburetor into the intake pipe being care ful to align the lug on the carburetor with the align ment tabs on the air intake pipe then tighten the clamp securely Manual ...

Page 66: ...n E clip then con nect the speedometer sensor plug KC255 KC248 10 Connect the oil temperature connector and cooling fan connector then using new O rings install the oil fittings onto the crankcase and secure with the cap screws Tighten to 8 ft lb KC249 KC250 KC251 11 If the brake pedal was removed during disassem bling apply grease to the brake pedal pivot stud then install the brake pedal and sec...

Page 67: ...lls see Steering Frame 14 Pour the appropriate quantity and grade oil into the crankcase then connect the negative battery cable and move the ATV outside to a well ventilated area 15 Start the engine and allow the engine to warm up while checking for oil leaks then shut the engine off and check the oil level Add oil as required Manual Table of Contents ...

Page 68: ...sure plunger extension Measurement A should be 18 6 19 1 mm KC328B 3 Connect Electric Choke Test Harness to the choke connector and a suitable 12 DC volt power supply for 2 3 minutes Disconnect the power and measure plunger extension Measurement B should be 22 1 23 4 mm KC328C 4 If the choke is damaged or the measurements are not within specifications the choke must be replaced INSTALLING 1 Lightl...

Page 69: ... the four Phillips head screws securing the top cover then remove the cover KC0019A KEY 1 Cover 2 Screw 3 Spring 4 Vacuum Piston 5 Spring Seat 6 Jet Needle 7 Needle Jet 8 Jet Holder 9 Main Jet 10 Slow Jet 11 Starter Jet 12 Float Valve 13 Clip 14 Float 15 Float Pin 16 Pilot Screw 17 Spring 18 Washer 19 O Ring 20 Idle Adjust Screw 21 Washer 22 Spring 23 Plate 24 Screw 25 Electric Choke 26 Choke Cove...

Page 70: ...mbly spring and U ring in the housing CC748 4 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring KC0022A KC0063A 5 Remove the float pin KC0024A 6 Lift the float assembly from the carburetor Account for the float valve and clip KC0025A NOTE Note the locations of the jets pilot screw and holder for disassembling procedures CC761A Manual Table of...

Page 71: ...or cracks and tears in the rubber 7 Inspect float for damage 8 Inspect gasket and O rings for distortion tears or noticeable damage 9 Inspect tips of the jet needle pilot screw and the needle jet for wear damage or distortion 10 Inspect the slow jet and main jet for obstructions or damage NOTE If the slow jet is obstructed the mixture will be extremely lean at idle and part throttle operation 11 I...

Page 72: ...ssembly with float valve into posi tion and secure to the carburetor with the float pin KC0024 NOTE Check float height by placing the carburetor on its side w float contacting the needle then mea sure with a caliper the height when the float arm is in contact with the needle valve Float arm height should be 17 mm KC0035 6 Place the float chamber into position making sure the O ring is properly pos...

Page 73: ...hillips head screws Tighten securely KC0019A INSTALLING 1 Connect the vent hose to the carburetor then connect the electronic choke connector and install the throttle cable onto the throttle arm KC264A KC263 2 Adjust the throttle cable free play to specifications see Periodic Maintenance then tighten the jam nut securely and install the throttle arm cover CAUTION It is important to press down on t...

Page 74: ... throttle cable free play see Periodic Mainte nance Engine RPM Idle To adjust the idle RPM see Periodic Maintenance Gas Tank REMOVING 1 Turn the gas tank valve to the OFF position then remove the seat and side panels 2 Remove the cap screws A securing the rear of the front body to the frame then remove two reinstall able rivets B securing the gas tank cover to the body KC219A WARNING Whenever any ...

Page 75: ...henever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Clean all gas tank components with parts cleaning solvent 2 Inspect all hoses for cracks or leaks 3 Inspect tank cap and tank for leaks holes and dam aged threads INSTALLING 1 Using a block to hold the front body open place the gas tank into position in the frame making sure the heat shield is in position ...

Page 76: ...Filter Oil Pump NOTE Whenever internal engine components wear excessively or break and whenever oil is contami nated the oil pump should be replaced The oil pump is not a serviceable component Testing Oil Pump Pressure 1 Connect the Tachometer to the engine 2 Connect the Oil Pressure Test Kit to the oil filter drain plug KC195A KC267 NOTE Some oil seepage may occur when installing the oil pressure...

Page 77: ... from the fittings on the cooler 2 Remove the cap screws securing the oil cooler to the frame Account for grommets AL651D 3 Remove the oil cooler from the frame INSTALLING 1 Place the cooler into position in the frame 2 Secure the cooler to the frame with the cap screws and grommets 3 Install the hoses onto their respective fittings and secure with the clamps KEY 1 Oil Cooler Assy 2 Oil Cooler 3 F...

Page 78: ...ght Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 2 Main jet obstructed 3 Needle jet obstructed 4 Vacuum piston not operating properly 5 Filter obstructed 6 Float height incorrect 1 Shift into higher gear decrease RPM speed 2 Clean main jet 3 Clean needle jet 4 Check piston operation 5 Clean filter 6 Adjust float height Problem Overflow and fuel leve...

Page 79: ...s not used for more than two weeks or as required by battery drain 800E 1 When charging a battery in the vehicle be sure the ignition switch is in the OFF position 2 Clean the battery terminals with a solution of baking soda and water NOTE The sealing strip should NOT be removed and NO fluid should be added 3 Be sure the charger and battery are in a well venti lated area Be sure the charger is unp...

Page 80: ...ns bring the battery to an authorized Arctic Cat dealer for further troubleshoot ing RPM Limiter NOTE The ATV is equipped with a CDI unit that retards ignition timing when maximum RPM is approached When the RPM limiter is activated it could be misinterpreted as a high speed misfire Testing Electrical Components All of the electrical tests should be made using the Fluke Model 73 Multimeter or Fluke...

Page 81: ... the oil NOTE Neither the switch nor the thermometer should be allowed to touch the bottom of the con tainer or inaccurate readings will occur Use wire holders to suspend switch and thermometer 733 554C 3 On the oil temperature switch when the oil tempera ture reaches 160 C 320 F the meter should read a closed circuit 4 On the oil temperature switch allow the oil to cool and when the temperature i...

Page 82: ...se compress the locking tabs on either side of the fuse case and lift out 0411 837 KC210A NOTE The ignition switch must be in the LIGHTS position 1 Remove all fuses from the distribution module 2 Set the meter selector to the DC Voltage position 3 Connect the black tester lead to ground 4 Using the red tester lead contact each end of the fuse holder connector terminals individually 5 The meter mus...

Page 83: ...t the black tester lead to the other end of the cap AR603D 2 The meter reading must be within specification NOTE If the meter does not read as specified replace the spark plug cap PEAK VOLTAGE NOTE All of the peak voltage tests should be made using the Fluke Model 73 Multimeter or Fluke Model 77 Multimeter with Peak Voltage Reading Adapter If any other type of tester is used readings may vary due ...

Page 84: ...ition switch harness connects to the switch with a three pin connector To access the connector remove the access panel in front of the handlebar KC339D VOLTAGE NOTE Perform this test on the main harness con nector 1 Set the meter selector to the DC Voltage position 2 Connect the red meter lead to the red white wire then connect the black meter lead to ground 3 Meter must show battery voltage NOTE ...

Page 85: ...the other tester wire to the green red wire The meter must show less than 1 ohm 3 Depress and hold the reverse override button The meter must show an open circuit NOTE If the meter does not show as specified replace the switch Gear Position Switch The gear position switch connector is located on the right side of the engine over the V belt housing KC227A To troubleshoot the switch use the followin...

Page 86: ...st be within specification Starter Relay 1 Remove the seat then using the multimeter set to the DC Voltage position check the relay as follows 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 NOTE Make sure that the ignition switch is in the ON position transmi...

Page 87: ...ble to perform a CDI peak voltage test see Ignition Coil in this section and or perform a continuity test of the wiring harness from the CDI connector to the CDI unit Regulator Rectifier The regulator rectifier is located under the front rack and front fenders above the oil cooler TESTING 1 Start engine and warm up to normal operating tempera tures then connect a multimeter to the battery as follo...

Page 88: ... to the brown blue wire 3 The meter must show battery voltage NOTE If the meter does not show voltage inspect fuses wiring harness connectors and switches Voltage Brakelights NOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the ON position and the brake either foot pedal or hand lever must be applied 1 Set the meter selector to the DC Voltage p...

Page 89: ...nition Timing The ignition timing cannot be adjusted however verify ing ignition timing can aid in troubleshooting other com ponents To verify engine timing see Periodic Maintenance Manual Table of Contents ...

Page 90: ...eplace tighten stator wires 2 Replace stator coils 3 Replace regulator rectifier Problem Alternator charges but charging rate is below the specification Condition Remedy 1 Stator wires shorted open loose at terminals 2 Stator coils grounded open 3 Regulator rectifier defective 4 Battery defective 5 Electrolyte low 1 Repair tighten Stator wires 2 Replace stator coils 3 Replace regulator rectifier 4...

Page 91: ...Charge battery add distilled water Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Charging system not charging 3 Battery overcharged damaged 4 Battery short circuited 5 Specific gravity too low 1 Replace battery 2 Check alternator regulator rectifier circuit connections 3 Replace battery correct charging system 4 Replace battery 5 Charge battery add distilled ...

Page 92: ...k 7 Remove the upper and lower ball joint cap screws taking care not to strip the threads AF628D 8 Pull the steering knuckle away from the axle taking care not to damage the seals as the axle clears the knuckle KC314 9 Support the axle to not allow it to drop or hang 10 Pull out on the axle until completely extended then push it back in approximately one half inch and pull out sharply Repeat until...

Page 93: ...may vary from model to model The technician should use dis cretion and sound judgment 1 Remove the cap screws securing the front drive actu ator and remove the actuator CD102 2 Remove the cap screws securing the pinion housing then using a rubber mallet remove the housing Account for a gasket Note the location of all the components for assembling purposes 3 Using a side cutter remove the boot clam...

Page 94: ... with the existing snap ring making sure the sharp edge of the snap ring faces to the outside AF993 AF994 2 Install the input shaft seal making sure it is flush with the edge of the housing 3 Lubricate the input shaft splines with High Perfor mance 2 Molybdenum Disulphide Grease NOTE Any time drive splines are separated clean all splines with parts cleaning solvent and dry with compressed air then...

Page 95: ... the ID tag location for assembling purposes KX173 3 Using a plastic mallet tap lightly to remove the dif ferential cover Account for an O ring and a shim NOTE If the cover is difficult to remove pry on the cover in more than one recessed location GC063 4 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 KX1...

Page 96: ... therefore it is very impor tant to properly adjust any gear set prior to final assem bly The following procedure can be used on both front differ ential or rear drive gear case NOTE All bearings must be installed in the gear case and the pinion properly installed before pro ceeding Backlash NOTE Always set backlash prior to any other shim ming 1 Install the existing shim or a 0 051 0 055 in shim ...

Page 97: ...ngle and on the index mark GC070 GC072A 6 Zero the dial indicator then while holding the pinion stationary rock the ring gear assembly forward and back and record the backlash Backlash must be 0 011 0 015 in If backlash is within specifications proceed to Ring Gear End Play If backlash is not within specifications increase shim thickness to increase backlash or decrease shim thickness to decrease ...

Page 98: ...button 1 Install the thrust button with shim into the gear case cover and tighten securely left hand threads GC057A 2 Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge Clearance should be 0 002 0 004 in GC058A 3 If clearance is as specified remove the ring gear and thrust button then place a drop of red Loctite 271 on ...

Page 99: ... lb CD110 Removing Needle Bearing NOTE Removing the needle bearing is rarely nec essary Avoid removing the needle bearing unless the bearing is clearly damaged NOTE This procedure can be performed on a rear gear case 1 Place a 1 4 in drill bit on the inside surface of the needle bearing against the bottom side then drill through the pinion shaft needle bearing housing CC885 2 Using a propane torch...

Page 100: ... CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock col lar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool GC066 2 Using a press remove the bearing CC900 3 Using a...

Page 101: ...screws and nuts Tighten to 38 ft lb KC291A 2 Install the cap screws securing the flange couplers together and tighten to 20 ft lb AG925 3 Install the front axles see Drive Axles in this sec tion AF610D AF897D 4 Install the wheels and tighten to 40 ft lb 5 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid gear lubricant into the differential and install the filler plug Tighten to 16 ft lb 6 Remove the ATV...

Page 102: ...ive axle into place in the gear case NOTE To assure proper seating of the axle give it a light pull the axle should remain clipped in place 2 Swing the knuckle up and onto the drive axle then place the knuckle into place in the upper A arm Secure the knuckle to the A arm with a cap screw and a new lock nut Tighten to 35 ft lb 3 Place the hub into position on the axle followed by a hex nuts Tighten...

Page 103: ...the left side of the frame then secure it to the frame with cap screws and lock nuts Tighten to 38 ft lb 2 Secure the engine output flange to the rear gear case input flange with four cap screws and lock nuts Tighten to 20 ft lb 3 Install the rear drive axles see Drive Axles in this section Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the cot...

Page 104: ... spread a new cotter pin making sure each side of the pin is flush to the hub nut KC305 7 Install the wheel and tighten to 40 ft lb 8 Remove the ATV from the support stand Hand Brake Lever Master Cylinder Assembly NOTE The master cylinder is a non serviceable component it must be replaced as an assembly REMOVING 1 Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the...

Page 105: ...and replace with new DOT 4 brake fluid from an unopened container Brake fluid readily absorbs moisture from the air signifi cantly 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 4 Compress the caliper holder against the caliper oppos...

Page 106: ...for damage and excessive wear NOTE For measuring brake pads see Periodic Maintenance 3 Inspect the brake caliper housings for scoring in the piston bores chipped seal ring grooves or signs of corrosion or discoloration 4 Inspect the piston surface for scoring discoloration or evidence of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals i...

Page 107: ...ch 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 9 Install the wheel Tighten to 40 ft lb 10 Remove the ATV from the support stand and verify brake operation CAUTION If brake pads become contaminated with brak...

Page 108: ...Replace joint 5 Replace gear s 6 Replace gears 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 Rep...

Page 109: ...st be replaced INSTALLING 1 Place bushings and sleeves where appropriate into shock eyelet then install shock with cap screws and nuts Tighten all nuts to 35 ft lb 2 Remove the ATV from the support stand Front A Arms REMOVING 1 Secure the ATV on a support stand to elevate the front wheels then remove the wheels 2 Remove the cotter pin from the nut Discard the cot ter pin 3 Remove the nut securing ...

Page 110: ...e splines then install the hub assembly onto the drive axle 7 Secure the hub assembly with the nut Tighten only until snug 8 Secure the brake caliper to the knuckle with the two patch lock cap screws Tighten to 20 ft lb 9 Secure the hub nut from step 7 to the shaft axle Tighten to 200 ft lb 10 Install a new cotter pin and spread the pin to secure the nut 11 Install the wheel and tighten to 40 ft l...

Page 111: ... new lock nut Tighten to 35 ft lb 11 Secure the boot guard to the lower A arm with the two cap screws Tighten securely 12 Install the wheel and tighten to 40 ft lb 13 Remove the ATV from the support stand Wheels and Tires TIRE SIZE The ATV is equipped with low pressure tubeless tires of the size and type listed in the General Information sec tion Do not under any circumstances substitute tires of ...

Page 112: ... the tires with the smallest circumference measurement until all tires are equal in circumference 6 Repeat steps 4 5 as necessary to ensure proper han dling 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 1 Replace spring s 2 Replace shock absorber 3 Adjust sh...

Page 113: ... caps and move the handlebar out of the way Account for the two han dlebar caps KC0058 3 Remove the cap screws securing the upper steering post to the frame Account for the housing cap outer housing and inner housing KC307A 4 Remove the cotter pins from the inner tie rod ends then remove the nuts and disconnect the inner tie rod ends KC184A NOTE If tie rods are to be completely removed remove the ...

Page 114: ...housings of the upper steering post support then with the housing cap in place secure with the cap screws Tighten to 20 ft lb KC307A 3 Using red Loctite 271 on the threads install the tie rod ends into the lower steering post arm and tighten to 30 ft lb then install new cotter pins KC184A 4 Place the handlebar and caps in place on the steering post and with the handlebar correctly positioned tight...

Page 115: ... INSTALLING 1 Apply a liberal amount of Handlebar Grip Adhesive to the inside of the new grip 2 Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up NOTE A quick firm push is required to seat the grip completely on the handlebar Install while the glue is wet 3 Wipe off any excess glue then secure the grip with the plug end cap and cap screw Throttle...

Page 116: ...ttle cable free play see Periodic Mainte nance Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the wheel cap from the hub then remove the cotter pin from the nut 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 ro...

Page 117: ...h the two cap screws Tighten to 35 ft lb KC313A 3 Install the tie rod end and secure with the nut 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 5 Install the hub assembly onto the splines of the shaft 6 Secure the hub assembly with the nut Tighten only until snug KC...

Page 118: ...mark the center of each front tire at a height parallel to the belly panel AF789D 7 Measure the distance between the marks at a height parallel to the belly panel at the front side then record the measurement 8 Push the ATV forward until the marks are parallel to the belly panel on the back side then measure the distance between the marks 9 The difference in the measurements must show 1 8 1 4 in t...

Page 119: ...osition and install the through bolt Start the lock nut and fin ger tighten only 2 Install the existing fasteners in the upper support tubes to frame and the front rack cap screws Tighten the lock nut from step 1 to 20 ft lb then tighten the cap screws securely Front Body Panel Fender REMOVING 1 Remove the seat and both side panels 2 Remove the front rack then disconnect the head light running lig...

Page 120: ... fender panel onto the ATV With the front rack in place loosely install the front rack hardware 2 Connect the electrical connectors under the electric panel then connect the light connectors and attach onto the frame KC210G KC224 3 Install the screws securing the front body to the front body supports then install the left side and right side footwell fasteners Do not tighten at this time 4 Place t...

Page 121: ...two exhaust springs Rear Body Panel Rack REMOVING 1 Remove the rear rack then remove two cap screws securing the rear body panel fender to the side frame and the cap screws securing the rear fenders to the footwells KC317A KC316 2 Disconnect the battery negative cable first and remove from the battery compartment then discon nect the starter relay wires and route the wiring out of the compartment ...

Page 122: ...n all fasten ers securely KC317A KC320A 2 Connect the light connectors and secure to the frame then install the battery starter relay and auxiliary brake Connect all wiring making sure to connect the positive cables first KC279 KC322 3 Secure the rear fenders to the footwells and tighten the nuts securely 4 Install the side panels and seat Seat REMOVING INSTALLING 1 To remove the seat lift up on t...

Page 123: ...g nuts wheel studs 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Re...

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