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Arctic Cat 2014 400 TRV, Service Manual

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TABLE OF CONTENTS

General Information ................................................. 2

General Specifications .................................................... 2
Torque Specifications ...................................................... 2
Torque Conversions (ft-lb/N-m) ....................................... 3
Break-In Procedure ......................................................... 3
Gasoline - Oil - Lubricant ................................................ 4
Genuine Parts ................................................................. 4
Preparation For Storage.................................................. 5
Preparation After Storage ............................................... 5

Periodic Maintenance .............................................. 6

Periodic Maintenance Chart............................................ 6
Lubrication Points............................................................ 7
Air Filter........................................................................... 7
Valve/Tappet Clearance .................................................. 7
Testing Engine Compression .......................................... 8
Spark Plug ...................................................................... 9
Muffler/Spark Arrester..................................................... 9
Engine/Transmission Oil - Filter  ..................................... 9
Front Differential/Rear Drive Lubricant.......................... 10
Nuts/Bolts/Cap Screws ................................................. 11
Headlights/Taillight-Brakelight ....................................... 11
Shift Lever ..................................................................... 12
Hydraulic Brake Systems .............................................. 13
Burnishing Brake Pads.................................................. 15
Checking/Replacing V-Belt............................................ 15

Steering/Body/Controls ......................................... 17

Seat............................................................................... 17
LCD Gauge ................................................................... 18
Front Rack..................................................................... 18
Front Bumper Assembly................................................ 18
Front Body Panel/Side Panels ...................................... 18
Footrests ....................................................................... 20
Belly Panel .................................................................... 20
Rear Body Panel/Rack .................................................. 21
Steering Post/Tie Rods ................................................. 22
Handlebar Grip.............................................................. 23
Throttle Control ............................................................. 24
Steering Knuckles ......................................................... 25
Measuring/Adjusting Toe-Out........................................ 27
Shift Lever ..................................................................... 28
Exhaust System ............................................................ 28
Taillight Assembly.......................................................... 29
Troubleshooting............................................................. 30

Engine/Transmission ............................................. 31

Specifications ................................................................ 31
Troubleshooting............................................................. 32
Removing Engine/ Transmission................................... 34
Top-Side Components .................................................. 36
Removing Top-Side Components ................................. 36
Servicing Top-Side Components................................... 39
Installing Top-Side Components ................................... 47
Left-Side Components .................................................. 51
Removing Left-Side Components ................................. 52
Installing Left-Side Components ................................... 54
Right-Side Components ................................................ 55
Removing Right-Side Components............................... 55
Servicing Right-Side Components ................................ 58
Installing Right-Side Components................................. 59
Center Crankcase Components.................................... 63

Separating Crankcase Halves....................................... 63
Disassembling Crankcase Half ..................................... 64
Servicing Center Crankcase Components .................... 65
Assembling Crankcase Half .......................................... 70
Joining Crankcase Halves............................................. 73
Installing Engine/Transmission ...................................... 74

Fuel/Lubrication/Cooling ....................................... 77

Carburetor Schematics ................................................. 77
Carburetor ..................................................................... 77
Electric Choke ............................................................... 82
Throttle Cable Free-Play ............................................... 82
Engine RPM (Idle)......................................................... 83
Gas Tank ....................................................................... 83
Oil Filter/Oil Pump ......................................................... 83
Testing Oil Pump Pressure............................................ 84
Vacuum Pulse Fuel Pump ............................................. 84
Troubleshooting ............................................................. 85

Electrical System ................................................... 86

Electrical Connections................................................... 86
Battery........................................................................... 86
RPM Limiter .................................................................. 87
Testing Electrical Components...................................... 87
Accessory Receptacle/Connector ................................. 87
Brakelight Switch (Auxiliary).......................................... 87
Brakelight Switch (Handlebar Control) .......................... 88
Oil Temperature and Cooling Fan Switches .................. 89
Fan Motor ...................................................................... 89
Power Distribution Module (PDM) ................................. 89
Ignition Coil ................................................................... 90
Speed Sensor ............................................................... 91
Ignition Switch ............................................................... 91
Handlebar Control Switches.......................................... 92
Drive Select Switch ....................................................... 93
Stator Coil ..................................................................... 93
Starter Relay ................................................................. 94
Starter Motor ................................................................. 95
CDI Unit......................................................................... 95
Regulator/Rectifier ........................................................ 95
Headlights ..................................................................... 96
Taillight - Brakelight ....................................................... 96
Ignition Timing............................................................... 96
Troubleshooting ............................................................. 97

Drive System/Brake System.................................. 99

Front Drive Actuator ...................................................... 99
Front Differential .......................................................... 100
Drive Axles .................................................................. 112
Rear Gear Case .......................................................... 114
Hub.............................................................................. 115
Hand Brake Lever/Master Cylinder Assembly............. 116
Hydraulic Brake Caliper............................................... 118
Troubleshooting Drive System..................................... 121
Troubleshooting Brake System.................................... 121

Suspension ........................................................... 122

Shock Absorbers ......................................................... 122
Front A-Arms ............................................................... 123
Rear A-Arms ............................................................... 125
Wheels and Tires ........................................................ 127
Troubleshooting ........................................................... 128

Summary of Contents for 2014 400 TRV

Page 1: ...400 TRV ATV SERVICE MANUAL 2014 ...

Page 2: ...quire one or more special tools to be completed The technician should use sound judgement when determining which proce dures can be completed based on their skill level and access to appropriate special tools Arctic Cat ATV publications and decals display the words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related inform...

Page 3: ...ide Components 55 Removing Right Side Components 55 Servicing Right Side Components 58 Installing Right Side Components 59 Center Crankcase Components 63 Separating Crankcase Halves 63 Disassembling Crankcase Half 64 Servicing Center Crankcase Components 65 Assembling Crankcase Half 70 Joining Crankcase Halves 73 Installing Engine Transmission 74 Fuel Lubrication Cooling 77 Carburetor Schematics 7...

Page 4: ...mm 1 8 1 4 in ELECTRICAL SYSTEM Ignition Timing 10 BTDC 1500 RPM Spark Plug Cap 5000 ohms Ignition Coil Resistance primary secondary Less than 1 ohm 5200 7800 ohms Ignition Coil primary CDI Peak Voltage 142 215 DC volts Stator Coil Resistance trigger charging 160 240 ohms Less than 1 ohm Peak Voltage trigger 2 0 volts or more AC Generator Output no load 60 AC volts 5000 RPM Generator Output approx...

Page 5: ...Steel Hub 40 54 Wheel Aluminum Hub 80 108 Rear Gear Case Frame 38 52 Engine Output Shaft Rear Gear Case Input Flange 20 27 Thrust Button Gear Case Cover 8 11 ENGINE TRANSMISSION Crankshaft Bushing Crankshaft 25 34 Speed Sensor Housing Crankcase 8 11 Clutch Shoe Crankshaft 221 300 Clutch Cover Housing Assembly Crankcase 8 11 Crankcase Half 6 mm Crankcase Half 8 11 Crankcase Half 8 mm Crankcase Half...

Page 6: ...80W 90 hypoid This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives FILLING GAS TANK Since gasoline expands as its temperature rises the gas tank must be filled to its rated capacity only Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area ATV0049B Tighten the ...

Page 7: ...g the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free riding Arctic Cat recommends the following procedure to pre pare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the exhaust system 3 Check all control wires and cables for signs of wear or fraying Replace if necessary 4 Change the engine transmission oil and filter 5 Ch...

Page 8: ... 0444 255 Item Initial Service After Break In First Month or 100 Miles Every Day Every Month or Every 100 Miles Every 3 Months or Every 300 Miles Every 6 Months or Every 500 Miles Every Year or Every 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 Gas Vent Hoses...

Page 9: ...the element to remove excess oil 9 Clean any dirt or debris from inside the air cleaner 10 Install the air filter frame assembly and cover 11 Install the storage compartment and cover CHECKING AND CLEANING DRAINS 1 Inspect the drains beneath the main housing for water oil and for proper sealing FI704A 2 Replace any drain that is cracked or shows any signs of hardening or deterioration 3 Wipe any a...

Page 10: ... screws are with the proper cover Tighten the cap screws securely 5 Install the spark plug Testing Engine Compression To test engine compression use the following procedure 1 Remove the high tension lead from the spark plug 2 Using compressed air blow any debris from around the spark plug 3 Remove the spark plug then attach the high tension lead to the plug and ground the plug on the cylinder head...

Page 11: ...ler Spark Arrester At the intervals shown in the Periodic Maintenance Chart clean the spark arrester using the following proce dure 1 Remove the three cap screws securing the spark arrester assembly to the muffler then loosen and remove the arrester CF105A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket is damaged...

Page 12: ...and thread into the engine case 12 Remove the oil level stick the oil level must be within the operating range but not exceeding the upper mark GZ461A 13 Inspect the area around the drain plug and oil filter for leaks Front Differential Rear Drive Lubricant When changing the lubricant use approved SAE 80W 90 hypoid gear lube To check lubricant remove the fill plug the lubricant level should be one...

Page 13: ...on of a headlight is fragile HANDLE WITH CARE When replacing a headlight bulb do not touch the glass portion of the bulb If the glass is touched it must be cleaned with a dry cloth before installing Skin oil residue on the bulb will shorten the life of the bulb To replace a headlight bulb use the following procedure 1 Rotate the bulb assembly counterclockwise and remove from the headlight housing ...

Page 14: ... most intense beam is centered on the verti cal mark 5 cm 2 in below the horizontal mark on the aiming surface 7 Adjust each headlight by turning the adjuster knob clockwise to raise the beam or counterclockwise to lower the beam CD714A Shift Lever CHECKING ADJUSTMENT CF130B Stop the ATV completely and shift the transmission into the R position The reverse gear indicator light should be illuminate...

Page 15: ...the level in the reservoir is adequate the sight glass will appear dark If the level is low the sight glass will appear clear On the auxiliary brake the level must be between the MIN and MAX lines on the res ervoir CF295A AL681 2 Compress the brake lever pedal several times to check for a firm brake If the brake is not firm the system must be bled 3 To bleed the main brake system use the following...

Page 16: ...before the bleeding procedure is continued Fail ure to maintain a sufficient amount of fluid in the reservoir will result in air in the system D Repeat step B and C until the brake pedal is firm 5 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 ins...

Page 17: ...ake to decelerate to 0 5 mph 3 Repeat procedure on each brake system twenty times 4 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed Checking Replacing V Belt REMOVING 1 Remove the right side footrest see Steer ing Body Controls 2 Remove the cap screws securing the V belt cover noting the location of the different lengthed cap screws for inst...

Page 18: ...with red Loctite 271 Tighten the nut to 165 ft lb KC152 NOTE At this point the push bolt can be removed 3 Rotate the V belt and clutches until the V belt is flush with the top of the driven clutch 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...

Page 19: ...ndles to the rear and rotate them to the vertical position CF226 2 Lift the rear of the seat up then pull slightly to the rear and lift the seat off the mountings CF227A 3 To lock the seat into position engage the two front mounting lugs into the mounting rack then holding down firmly on the front of the seat push the seat forward until the rear tabs engage the rear mounting latches CF229A 4 Lock ...

Page 20: ...e two flange bolts and lock nuts securing the upper bumper supports to the bumper 2 Remove the through bolt and lock nut securing the bumper to the frame then remove the bumper CLEANING AND INSPECTING 1 Clean all bumper components with parts cleaning solvent 2 Inspect all welds for cracking or bending INSTALLING 1 Place the front bumper assembly into position and install the through bolt Start the...

Page 21: ... panel to the rear and lift the rear up to clear the handlebar CD765A NOTE It may be necessary to rotate the body panel to the right to align the opening with the handlebar CLEANING AND INSPECTING 1 Clean all fender components with warm soap and water 2 Inspect fenders for cracks and or loose rivets 3 Inspect for any missing decals INSTALLING 1 Rotate the handlebar to the full left position then p...

Page 22: ...crews and flange nuts secur ing the front and rear fenders to the footwells CD691A 2 Remove the screws securing the foot pegs to the footrests then remove the foot pegs and footwells 3 Remove the cap screws and flange nuts securing the footrests to the frame then remove the footrests CLEANING AND INSPECTING 1 Clean the footrest in parts cleaning solvent 2 Inspect the footrest weldments for cracks ...

Page 23: ...l components with warm soap and water 2 Inspect side panels and rear body panel for cracks and loose rivets 3 Inspect threaded areas of all mounting bosses for stripping 4 Inspect for missing decals INSTALLING 1 Remove the gas tank cap and set the rear body panel in position then install the cap and connect the tail light brakelight connector 2 Place the rear rack in position with the bushings and...

Page 24: ... Remove two cap screws securing the upper steering post bearing to the frame Account for two housings CD760 8 Using a suitable lift stand raise the ATV enough to remove the front wheels 9 Remove the cotter pins and slotted nuts from the inner and outer tie rod ends then remove the tie rods from the steering post arm and the left side and right side steering knuckles AF778D KX039 10 Remove two cap ...

Page 25: ...he cotter pins AF778D 4 Install the front wheels and tighten to 40 ft lb steel wheels or 80 ft lb aluminum wheels using a criss cross pattern 5 Lower the ATV and place the handlebar and caps into position on the steering post then position the LCD gauge on top of the caps and secure with the four cap screws Tighten securely 6 Install the storage compartment box then attach the storage compartment ...

Page 26: ...seated with the smooth part of the grip facing up 3 Wipe off any excess glue then secure the grip with the handlebar end cap Throttle Control REMOVING 1 Remove the two machine screws securing the throt tle control to the handlebar 2 Slide the grommet out of the lower half of the throt tle control then remove the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer secur...

Page 27: ...move the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then remove the knuckle 9 Remove the snap ring from the knuckle then remove the bearing PR287A PR288 CLEANING AND INSPECTING 1 Clean all knuckle components 2 Inspect the bearing for pits gouges rusting o...

Page 28: ...5 Install the hub assembly onto the splines of the shaft 6 Secure the hub assembly with the nut Tighten only until snug PR257 7 Secure the brake caliper to the knuckle with new patch lock cap screws Tighten to 20 ft lb PR264A 8 Pump the hand brake lever then engage the brake lever lock 9 Secure the hub nut from step 6 to the shaft Tighten to 200 ft lb 10 Install a new cotter pin and spread the pin...

Page 29: ...ved acces sories 4 Measure the distance from the outside edge of each handlebar grip to equal reference points on each DE047A 5 Adjust the handlebar direction until the two measure ments are equal then secure the handlebar to the rear rack using tie down straps NOTE Care must be taken not to allow the handle bar to turn while securing it CD014 6 Measure the distance from the inside of each front r...

Page 30: ...king the jam nuts make sure the ball joints are at the center of their normal range of motion and at the correct angle 733 559A Shift Lever REMOVING 1 Remove the E clip securing the shift rod to the shift lever 2 Remove two cap screws two self tapping screws and three nylon ties securing the left side splash panel and remove the panel 3 Remove the axle and nut securing the shift lever to the upper...

Page 31: ...l the two exhaust springs Taillight Assembly REMOVING 1 Unplug the three prong connector and free the tail light wiring harness from the frame 2 Remove the torx head cap screws securing the tail light assembly to the frame Account for any wash ers 3 Remove the taillight assembly INSPECTING 1 Inspect wiring harness three prong connector lens base cap screws and socket for damage 2 Inspect all wires...

Page 32: ...Tighten replace cap screws 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace fr...

Page 33: ...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 4 975 4 990 mm 4 955 4 970 mm Valve Stem Runout max 0 05 mm Valve Margin min intake exhaust 0 65 mm 0 75 mm Valve Face Seat Width min intake exhaust 2 12 mm 2 55 mm Valve Seat Angle intake exhaust 45 Valve Face Radial Runout max 0 15 mm Valve Spring Free...

Page 34: ...ve 4 Carburetor jets obstructed 5 Valve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 5 Valve tappets worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4...

Page 35: ...an element 9 Clean or replace hose 10 Adjust float height Problem Exhaust smoke dirty or heavy Condition Remedy 1 Engine oil overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil replace oil 2 Replace service rings cylinder 3 Replace guides 4 Replace service cylinder 5 Replace valves 6 Replace se...

Page 36: ... O rings then disconnect the oil temperature connector and cooling fan connector KC251 KC250 KC249 4 Disconnect the speedometer sensor then remove the E clip securing the shift rod to the shift arm and disconnect the shift rod Account for a bush ing and flat washer KC248 KC255 AT THIS POINT If the technician s objective is to service Top Side Components Left Side Components or Right Side Component...

Page 37: ...t 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 trig ger 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 output flanges then r...

Page 38: ...ssion stroke NOTE Arctic Cat recommends the use of new gaskets lock nuts and seals and lubricating all internal compo nents when servicing the engine transmission 1 Remove the cap screws securing the two tappet covers Remove the two tappet covers Account for the O rings MD1264 NOTE Keep the mounting hardware with the cov ers for assembly purposes 2 Remove the cylinder head cover cap screws Note th...

Page 39: ...e C ring down into the crankcase MD1131 7 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 cylinder head Account for an alignment pin NOTE Loop the chain over the cylinder and secure it with a wire to keep it from falling into the crankcase MD1132 8 Remove the cam chain tensioner by lifting it ...

Page 40: ...e right side of the cylinder to the right side crankcase half KC337A 13 Lift 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 14 Using an awl remove one piston pin circlip Take care not to drop it into the crankcase AT THIS POINT To service valves and cylinder head see Servicing Top Side Components...

Page 41: ...ve each ring by working it toward the dome of the piston while rotating it out of the groove Servicing Top Side Components 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 Cylinder Head Cover NOTE If the co...

Page 42: ...unt for an upper spring retainer CC994 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC134D CC136D NOTE The valve seals must be replaced 3 Remove the valve springs then invert the cylinder head and remove the valves Measuring Valve Stem Runout 1 Support each valve stem end with the V Blocks then check the valve stem runout using a dial indi cator ATV 1082 2 Max...

Page 43: ... then from top to bottom 4 Maximum wobble deflection must not exceed specifications Measuring Valve Guide Inside Diameter 1 Insert a snap gauge 1 2 way down into each valve guide bore then remove the gauge and measure it with a micrometer 2 Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance the cylinder head must be replaced Servicing Valves Valve...

Page 44: ...e piston for seizure marks or scuffing If piston is scored or galled replace it with a new one 4 Inspect the perimeter of each piston for signs of blowby indicated by dark discoloration Blowby is caused by worn piston rings exces sive carbon in ring grooves or an out of round cylinder Removing Piston Rings 1 Starting with the top ring slide one end of the ring out of the ring groove CC400D 2 Remov...

Page 45: ...icator into the piston pin bore Take two measurements to ensure accuracy The diameter must not exceed specifications If the diameter exceeds specifications the piston must be replaced ATV 1069 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder front to back in six places CC397D 2 Measure the corresponding piston diameter at a point 15 mm 0 6 in above the piston skirt at a right angle...

Page 46: ...0 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 assembly by continuing to move the cylin der head in a figure eight motion until a uniform bright metallic finish is attained CC996 Measuring Cylinder Head Dis...

Page 47: ...ments The trueness out of roundness is the difference between the highest and lowest 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 sur face using a 320 grit ball hone NOTE To produce the proper 60 cross hatch pattern use a l...

Page 48: ...aft to Cylinder Head Clearance 1 Loosen the jam nuts and adjuster screws CC005D 2 Place a strip of plasti gauge in each of the cam shaft lands in the cylinder head 3 Place the tappet cover on the cylinder head and secure with the cover cap screws Tighten to 8 ft lb NOTE Do not rotate the camshaft when measur ing clearance 4 Remove the cap screws securing the cylinder head cover to the cylinder the...

Page 49: ... motor oil then install the piston on the connecting rod making sure there is a cir clip on each side and the open end of the circlip is directed upwards or downwards NOTE The piston should be installed so the arrow points towards the exhaust MD1213 2 Place the two alignment pins into position Place a new cylinder gasket into position then place a pis ton holder or suitable substitute beneath the ...

Page 50: ...then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity MD1347 MD1163 7 Install the four cylinder head cap screws with washers Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left spark plug side Tighten only until snug CAUTION The cylinder should s...

Page 51: ...he inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface NOTE When the camshaft assembly is seated make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket 13 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the camshaft lobes onto the camshaft...

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

Page 53: ... then install the remaining cap screws Tighten only until snug MD1261 28 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 27 to 8 ft lb 29 Adjust valve tappet clearance see Periodic Main tenance 30 Place the two tappet covers with O rings into posi tion then install and tighten the cap screws to 8 ft lb MD1264 31 Install the spark plug and tight...

Page 54: ...case puller and the 6 mm adapter remove the left side cover w stator assembly Account for the two alignment pins and the position of the shifter bracket for installing purposes CC946 MD1188 NOTE Inspect the inside of the left side cover for any shaft washers that may have come off with the cover Make sure they are returned to their respec tive shafts and that the starter idler gear spacer is on th...

Page 55: ...ignment marks and washer for installing pur poses then release the cam stopper spring tension MD1239 9 Remove the shift detent cam 10 Remove the cam stopper assembly 11 Remove two starter motor cap screws KC217 12 Remove starter motor by tapping lightly with a mallet NOTE The starter motor is a non serviceable component and must be replaced as an assembly 13 Using an impact screwdriver remove the ...

Page 56: ...1239 6 Install starter idler gear No 2 and starter idler gear No 1 MD1305 7 Place the key into its notch then slide the rotor flywheel with the ring gear in place over the crankshaft Tighten the nut to 107 ft lb C Cover NOTE Steps 1 7 in the preceding sub section must precede this procedure 8 Install two alignment pins and place the left side cover gasket into position Install the left side cover ...

Page 57: ...A 2 Remove the cap screws securing the V belt cover to the clutch cover then slide the brake pedal out ward and remove the V belt cover Account for two alignment pins and a gasket KC142A 3 Mark the movable drive face and the fixed drive face for installing purposes then remove the nut holding the movable drive face onto the crankshaft MD1033 4 Remove the movable drive face and spacer Account for t...

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

Page 59: ...the word OUTSIDE for installing purposes MD1286 14 Remove the left hand threaded nut holding the centrifugal clutch assembly MD1014 MD1016 15 Remove the cam chain MD1335 16 Remove the oil pump drive gear cap screw MD1018 17 Remove oil pump drive gear Account for the pin CAUTION Care must be taken when removing the nut it has left hand threads ...

Page 60: ... screws securing the oil strainer cap then remove the Phillips head screws securing the oil strainer Account for the O ring CC091D Servicing Right Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoe for uneven wear chips cracks or discoloration 2 Inspect the depth of the grooves in the clutch shoes If any shoe is worn to the bottom of the groove replace the complete set AT...

Page 61: ...at the clutch shoe can only be rotated counterclockwise 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 an...

Page 62: ...Tighten to 8 ft lb MD1060 4 Place the thrust washer and drive pin into position on the oil pump shaft install the oil pump driven gear making sure the recessed side of the gear is directed inward and secure with a new snap ring NOTE Always use a new snap ring when install ing the oil pump driven gear MD1020 MD1019 5 Install the cam chain NOTE Keep tension on the cam chain to avoid damaging the cra...

Page 63: ...king sure to align the drive pin with the slot in the shift shaft KC325A KC326B B Clutch Cover C Fixed Drive Face D Movable Drive Face NOTE Steps 1 9 in the preceding sub section must precede this procedure 10 Install two alignment pins and place the clutch cover housing gasket into position Install the clutch cover MD1115 11 Tighten the clutch cover housing cap screws to 8 ft lb MD1117 12 Install...

Page 64: ...g until the faces open sufficiently to allow the V belt to drop into the pulley approxi mately 3 4 in KC137 NOTE The arrows on the V belt should point in direction of engine rotation 16 Making sure the movable drive face rollers are in position pinch the V belt together near its center and slide the spacer and movable drive face onto the shaft KC127 17 Coat the threads of the nut with red Loctite ...

Page 65: ... must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the left side and right side cap screws securing the crankcase halves noting the position of the different sized cap screws for j...

Page 66: ...ly A noting the location of the front and rear bearing locating pins and the center bearing locating ring FI660A FI659A FI661A 2 Remove the reverse idler assembly B Account for and note the location of the inner bushing 1 idler shaft 2 and outer washer 3 FI641A 3 Remove the driveshaft C then pull the shift fork locating shaft D out of the crankcase locating boss and allow the shift forks to diseng...

Page 67: ...taining nut From inside the crank case 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 SECONDARY GEARS NOTE When checking and correcting secondary gear backlash and tooth contact the universal joint must be secured to the front shaft or false measurements will occur CAUTION Do not remove the re...

Page 68: ...urement is within tolerance Note the following chart Checking Tooth Contact NOTE After correcting backlash of the second ary driven bevel gear it is necessary to check tooth contact 1 Remove the secondary driven output shaft assem bly 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 s...

Page 69: ... 2 Zero the indicator and push the small end of the connecting rod away from the dial indicator 3 Maximum deflection must not exceed specifica tions Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal CC289D 3 Acceptable gap range must ...

Page 70: ...4 2 Remove the splined washer then remove the reverse driven gear along with the bearing and bushing FI665 3 Remove the low driven gear washer then remove the low driven gear along with the bearing and bushing FI666 FI667 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 direct...

Page 71: ...ar along with the bearing and bushing and remove the high driven washer FI670 FI671 ASSEMBLING 1 With the high driven washer 1 on the counter shaft 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 counter shaft and secure with snap ring 7 then install the ...

Page 72: ...15 and splined washer 16 Secure with a snap ring FI665A FI664 5 Install the reverse dog on the shaft then place the shift forks and shift shaft into position FI663 FI662 NOTE The countershaft assembly is now ready to be installed Assembling Crankcase Half NOTE For ease of assembly install components on the right side crankcase half NOTE If the output driveshaft was removed make sure that the prope...

Page 73: ...ns to smoke then slide the crank shaft assembly into place MD1334 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft installer 4 Rotate the crankshaft so the counterweight is toward the rear of the engine Install the crank bal ancer shaft MD1024 5 Install the key in the crank balancer shaft then install the gear and aligning the timing marks slide the ge...

Page 74: ... an assembly FI662 FI653 8 Align the shift forks to allow engagement with the shift cam then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase FI653A FI655A 9 Install the input driveshaft FI646 10 Install the spacer 1 shaft 2 reverse idler gear and washer 3 FI641A FI645 ...

Page 75: ...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 then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws MD1008 4 From the left side install the remaining crankcas...

Page 76: ...h the flange nuts Tighten to 38 ft lb 3 Align the front and rear output flanges with the drive couplers then secure with the screws with red Loctite 271 and tighten to 20 ft lb KC242 KC243 4 Install the front and rear V belt cooling boots and secure with the existing hardware KC235 KC236 5 Connect the stator coil trigger coil and gear posi tion switch connectors then attach the engine ground cable...

Page 77: ...take pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe then tighten the clamp securely KC245A 8 Install the air filter housing onto the frame then connect the inlet air duct air silencer duct and intake housing to carburetor boot and tighten all hose clamps securely KC254 9 Install the shift rod onto the shift arm with bushing and flat washer and ...

Page 78: ...ecure with a flat washer and cap screw Tighten to 25 ft lb KC232A KC149A 12 Install the heat shield then install the gas tank see Fuel Lubrication Cooling 13 Install the front body panel front rack and foot wells see Steering Body Controls 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 ...

Page 79: ...rottle actuator cover to the carburetor then remove the cover PR154B 6 Remove the throttle cable from the actuator arm PR162C 7 Loosen the outer jam nut securing the throttle cable to the carburetor body then route the cable out of the way Description p n Oil Pressure Test Kit 0644 495 Seal Removal Tool 0644 072 Tachometer 0644 275 Electric Choke Test Harness 0444 247 KEY 1 Cover 2 Screw 3 Spring ...

Page 80: ...m piston assembly from the carbu retor body Account for a spring spring seat and the jet needle CC746 3 Remove the three screws securing the pump housing Account for the diaphragm assembly spring and U ring in the housing CC748 4 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring CC749 CC750 5 Remove the float pin CC752 6 Lift the float assemb...

Page 81: ...ipped threads and any imperfections in the cast ing 6 Inspect the vacuum piston diaphragm for cracks imperfections in the casting or cracks and tears in the rubber 7 Inspect float for damage 8 Inspect gasket and O rings for 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 obs...

Page 82: ...the needle then measure with a caliper the height when the float arm is in contact with the needle valve Float arm height should be 17 mm 0 7 in 6 Place the float chamber into position making sure the O ring is properly positioned then secure with the Phillips head screws CC750 CC749 7 Place the U ring into the pump housing Position the spring and diaphragm assembly lip toward the car buretor onto...

Page 83: ...nd secure by tightening the outer jam nut PR162B 4 Connect the throttle cable to the actuator arm PR162C 5 Place the throttle actuator cover into position on the carburetor then secure with the screw PR154B 6 Position the carburetor in the air cleaner boot and intake pipe assembly then secure with the clamps 7 Connect the hose from the carburetor to the gas tank 8 As necessary secure the air intak...

Page 84: ...ke 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 Lightly lubricate the O ring on the choke body then carefully insert the choke assembly into the carbure tor being carefu...

Page 85: ...r cracks or leaks 3 Inspect tank cap and tank for leaks holes and dam aged threads 4 Remove the fuel level sensor fuel pick up assembly and inspect the fuel level sensor and fuel screen INSTALLING 1 Install the fuel level sensor fuel pick up assembly 2 Place the gas tank into position in the frame then install the cap screws Tighten securely 3 Connect the gasline hose from the carburetor then conn...

Page 86: ...Information clogged oil passage clogged oil filter or improper installation of the oil filter Vacuum Pulse Fuel Pump The vacuum pulse fuel pump is not a serviceable compo nent If the pump fails it must be replaced TESTING 1 Disconnect the fuel pump carburetor hose at the fuel pump then connect a hose and suitable pressure gauge to the fuel pump output fitting CD815 2 Start the engine Fuel pump pre...

Page 87: ...bstructed loose 2 Slow jet outlet obstructed 3 Low speed fuel screw setting incorrect 4 Float height incorrect 1 Clean tighten jet 2 Clean outlet 3 Adjust screw 4 Adjust float height 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 inc...

Page 88: ...he vehicle be sure the ignition switch is in the OFF position NOTE Be sure to maintain the fluid of the battery at the UPPER LEVEL Use only distilled water when adding fluid to these batteries 2 Clean the battery terminals with a solution of baking soda and water 3 Be sure the charger and battery are in a well venti lated area and ensure the battery charger cables will not contact any battery acid...

Page 89: ...tlet NOTE If after charging the battery does not per form to operator expectations 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 ...

Page 90: ...dlebar Control To access the connector remove the access panel NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Connector 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the orange wire then connect the black tester lead to the red blue wire FI489 3 The meter must show battery voltage NOTE If the meter shows no battery voltage trouble ...

Page 91: ...e switch then install the switch and tighten securely 9 Connect the switch leads Fan Motor The connector is the black two prong one located above the radiator NOTE The ignition switch must be in the ON posi tion RESISTANCE Fan Motor Connector 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the blue wire then connect the black tester lead to the black wire FI501A 3 Th...

Page 92: ...s The relays are interchangeable NOTE The module and wiring harness are not a service able components and must be replaced as an assembly Ignition Coil The ignition coil is on the frame above the engine To access the coil the side panel must be removed see Steer ing Body Controls RESISTANCE NOTE For these tests the meter selector should be set to the OHMS position and the primary wire s should be ...

Page 93: ...lack tester lead to the ground lead G CD885A 3 Turn the ignition switch to the ON position 4 The meter must show 6 12 DC volts 5 Leave the black tester lead connected then con nect the red tester lead to the signal lead S pin 6 Slowly move the ATV forward or backward the meter must show 0 and 6 12 DC volts alternately NOTE If the sensor tests are within specifications the LCD gauge must be replace...

Page 94: ...witch Handlebar Control Switches The connector is the yellow one next to the steering post To access the connector the steering post cover and the right side fender splash shield must be removed see Steering Body Controls NOTE These tests should be made on the top side of the connector RESISTANCE HI Beam 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the yellow wire...

Page 95: ...eering post To access the connector the cover must be removed NOTE Resistance tests should be made with the connector disconnected and on the selector side of the connector RESISTANCE 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the red wire then connect the black tester lead to the white wire 3 With the select switch in the 2WD position the meter must show an ope...

Page 96: ...t the black tester lead to the blue wire 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Starter Relay 1 Remove the seat then using the multimeter set to the DC Voltage position check the relay as fol lows 2 Connect the red tester lead to the positive battery terminal then connect the black tester lead to the starter cable connection on the start...

Page 97: ...ecure with two machine screws and wiring forms 2 Secure the positive cable to the starter motor with the nut 3 Connect the battery positive cable first CDI Unit The CDI is located beneath the seat near the battery NOTE The CDI unit is not a serviceable component If the unit is defective it must be replaced The CDI is rarely the cause for electrical problems how ever if the CDI is suspected substit...

Page 98: ...o the white wire then connect the black tester lead to the black wire 3 With the ignition key in the LIGHTS position the meter must show battery voltage NOTE If the meter shows no voltage inspect fuses wiring harness connectors and switches VOLTAGE Brakelight 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 ...

Page 99: ...dy 1 Lead wires shorted open loose at terminals 2 Stator coil magneto grounded open 3 Regulator rectifier defective 4 Cell plates battery defective 5 Electrolyte low lead acid 1 Repair tighten lead wires 2 Replace stator coil 3 Replace regulator rectifier 4 Replace battery 5 Add distilled water Problem Battery overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier re...

Page 100: ...ry short circuited 4 Specific gravity too low 1 Check magneto regulator rectifier circuit connections 2 Replace battery correct charging system 3 Replace battery 4 Charge battery add distilled water Problem Battery polarity reversed Condition Remedy 1 Battery incorrectly connected 1 Reverse connections replace battery repair damage ...

Page 101: ...1 Disconnect the connector on the actuator harness 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the actuator AG926 3 Remove the mounting cap screw from below the actuator on the suspension side AG927 4 Loosen but do not remove the mounting cap screw at the front of the actuator then slide the actuator to the rear enough to clear the slotted mounting tab and ...

Page 102: ...ecure the wiring harness to the frame with a nylon cable tie Front Differential NOTE To remove the rear gear case see Rear Gear Case in this section REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the drain plug and drain the gear lubricant into a drain pan then reinstall the plug and tighten to 45 in lb ATV0082A 3 Remove the front wheels 4 Pump up the hand...

Page 103: ...ubber mallet tap the end of the axle and free it from the knuckle assembly AF628D 11 Pull the steering knuckle away from the axle KX151 12 Support the axle to not allow it to drop or hang 13 Remove the lower shock bolts Account for the lock nuts then move the shocks aside and secure them with a strap AF897D 14 Remove the upper A arm lock nuts and cap screws then remove the A arms CAUTION The axle ...

Page 104: ...move the three screws securing the front drive actuator to the gear case then remove the actuator AG925 18 Remove the lower differential mounting cap screw Account for a lock nut and washers CD026 19 Remove the upper differential mounting cap screws CD016 20 Free the differential assembly from the frame mount ings then shift the differential assembly forward enough to disengage the front driveshaf...

Page 105: ... 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 Using a boot clamp pliers or suitable substitute remove the boot clamps then remove the boots and splined drive from the input shaft 4 Remove the snap ring then remove the ...

Page 106: ...ap ring faces to the outside GC012 GC011 2 Install the input shaft seal making sure it is fully seated in 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 spli...

Page 107: ...ferential Assembly NOTE This procedure can be performed on a rear gear case 1 Using a T 40 torx wrench remove the cap screws securing the pinion 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 malle...

Page 108: ...the housing WC430 2 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing CC878 3 Secure the pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar and a bearing CC879 4 Remove any reusable parts from the gear case hous ing then discard the housing and lock collar Assembling Pinion Gear 1 Install the beari...

Page 109: ...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 on the gear case ...

Page 110: ... engages the locating hole in the cover then make sure the bear ing flange is completely seated in the cover GC032A GC033A 4 Install the existing shim or a 0 063 in shim on the cover side of the ring gear then place the assembled gear case cover onto the gear case and secure with three cap screws Tighten evenly using a crisscross pattern GC036B 5 Place the appropriate Backlash Measuring Tool into ...

Page 111: ...ith the cover side up then install a dial indicator contacting the ring gear axle flange GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008 in 3 To increase end play decrease the shim thickness To decrease end play increase the shim thickness NOTE Once proper backlash and end play are established the gear case can be assembl...

Page 112: ...plied to the O ring for ease of assembling NOTE If a new housing is being installed tighten the cap screws to 28 ft lb 6 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 CD110 Removing Installing Axle Seal NOTE This procedure can be performed on a rear g...

Page 113: ... Tighten to 16 ft lb 3 Install the front drive actuator with the three torx head cap screws then connect the wire connec tor to the main wiring harness AG925 4 Install the inner fender panels 5 Install the front axles see Drive Axles in this sec tion 6 Secure the upper A arms with cap screws and lock nuts Tighten to 50 ft lb AF610D 7 Secure the lower shock eyelets with cap screws and lock nuts Tig...

Page 114: ...ced with a new lock nut 8 While holding the drive axle stationary pull the top of the knuckle out and down until it is free of the drive axle 9 Place a drain pan under the ATV to contain any oil leakage 10 Push the axle shaft firmly toward the gear case to release the internal lock then while holding the axle in pull the CV cup from the gear case PR729B PR725A REMOVING FRONT DRIVE AXLE NOTE For re...

Page 115: ...m on the knuckle and secure with new patch lock cap screws Tighten the auxiliary brake caliper cap screws to 20 ft lb Tighten the hand brake caliper cap screws to 20 ft lb 5 Pump up the hand brake lever then engage the brake lever lock 6 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 hex nut NOTE If the cot...

Page 116: ...gine out put shaft to the rear gear case input flange CD028 4 Remove the two cap screws and lock nuts securing the rear gear case to the frame then remove the gear case through the left side AF960A 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 Acc...

Page 117: ...with blue Loctite 243 and lock nuts Tighten to 38 ft lb 2 Secure the engine output shaft 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 4 Install the left side rear A arms see Rear A Arms in Suspension Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel ...

Page 118: ... to the hex nut NOTE If the cotter pin does not line up always tighten to the next alignment PR260 7 Install the wheel and tighten to 40 ft lb steel wheels or 80 ft lb aluminum wheels 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...

Page 119: ...Inspect the banjo fitting for cracks and deterioration and the condition of the fittings threaded and com pression 5 Inspect the brakelight switch for corrosion cracks missing or broken mounting tabs or broken and frayed wiring NOTE If the brakelight switch is determined to be not serviceable see Electrical System INSTALLING 1 Position the brake housing on the handlebar Secure with clamp screws th...

Page 120: ...he bleed screw then remove the caliper 4 Compress the caliper holder against the caliper opposite the O ring side and remove the outer brake pad then remove the inner brake pad NOTE If brake pads are to be returned to service do not allow brake fluid to contaminate them PR237A PR238 5 Remove the caliper holder from the caliper and dis card the O ring PR239B WARNING Arctic Cat recommends that only ...

Page 121: ... pads 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 s...

Page 122: ...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 steel wheels or 80 ft lb aluminum wheels 10 Remove the ATV from the support stand and verify brake operation CAUTION If brake pads ...

Page 123: ... coupling 4 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...

Page 124: ...etainer and remove the spring AF730D CLEANING AND INSPECTING 1 Clean all shock absorber components using a pres sure washer 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock rods sleeves bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber spring over the shock absorber compress the spring ...

Page 125: ...ring the tie rod end to the knuckle then remove the tie rod end from the knuckle AF618D 7 Remove the cap screws securing the ball joints to the knuckle PR203 8 Tap the ball joints out of the knuckle then remove the knuckle 9 Remove the lower shock absorber eyelet from the upper A arm 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remove the circlip from the ball joint then rem...

Page 126: ... 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 then secure the hose to the A arm with a cable tie and grommet DE054A 4 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut to 50 ft lb 5 Secure the A arm assemblies to the frame mounts from step 2 Tighten the cap scre...

Page 127: ...ten to 40 ft lb steel wheels or 80 ft lb aluminum wheels 14 Remove the ATV from the support stand Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut Release the brake lever lock 5 Remove the caliper right side only NOTE Do not...

Page 128: ...t lb 3 Tighten the hardware securing the A arms to the frame mounts from step 1 to 50 ft lb 4 Apply grease on the drive axle splines then install the hub assembly onto the drive axle PR290 5 Secure the hub assembly with the nut Tighten only until snug 6 Secure the brake caliper to the knuckle with two new patch lock cap screws right side only Tighten the caliper to 20 ft lb NOTE Ensure that the br...

Page 129: ...cate forward direction of rotation AF612D 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 Be sure all tires are the specified size and have identical tread pattern NOTE If pulling is noted measure the circumfer ence of the fron...

Page 130: ...wheel oscillation Condition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Auxiliary brake adjusted incorrectly 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 1 Replace bearings 2 Replace tires 3 Replace rim 4 Tighten cap screws 5 Adjust brake 6 Replace bushing 7 ...

Page 131: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 845 ...

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