Arctic Cat 2015 XR Service Manual Download Page 1

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S E R V I C E M A N U A L

www.arcticcat.com

Summary of Contents for 2015 XR

Page 1: ...S E R V I C E M A N U A L www arcticcat com XR ...

Page 2: ...ompleted The technician should use sound judgement when determining which proce dures can be completed based on skill level and access to appropriate special tools All 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 information Be sure to follow the directive bec...

Page 3: ...ion 112 Fuel Lubrication Cooling 114 Throttle Body 114 Throttle Cable Free Play 115 Engine RPM Idle 115 Gas Tank 115 Testing Oil Pump Pressure 116 Liquid Cooling System 117 Troubleshooting 119 Electrical System 120 Battery 120 Accessory Receptacle Connector 121 Brakelight Switch 121 Engine Coolant Temperature ECT Sensor 122 Fan Motor 122 Power Distribution Module PDM 123 Ignition Coil 123 EFI Sens...

Page 4: ...2 0 AC volts or more AC Generator Output noload 75 AC volts 5000 RPM EXHAUST COMPONENTS Part Part Bolted To Torque ft lb N m Exhaust Pipe Engine 20 27 Spark Arrester Muffler 48 in lb 5 5 Heat Shield Exhaust Pipe 8 11 STEERING COMPONENTS Steering Shaft Frame 20 27 Steering Shaft Flange Frame 11 15 Steering Post Handlebar Block 20 27 Tie Rod End Knuckle Steering Shaft 55 74 EPS Housing Frame 35 47 H...

Page 5: ... 14 Crankcase Half 8 mm Crankcase Half 21 28 Starter Motor Crankcase 10 14 Shift Lever Shift Axle 8 11 Engine Mounting Through Bolt Frame 35 47 ENGINE TRANSMISSION 500 Cylinder Head Cap Screw Crankcase 28 38 Cylinder Head Nut Cylinder 20 27 Oil Pump Drive Gear Crankshaft 63 85 Cam Chain Tensioner Guide Cylinder Head 11 15 Cam Chain Tensioner Cylinder 10 14 Water Pump Drive Gear Crankshaft 28 38 EN...

Page 6: ...filter housing cover and air filter Start the engine and allow it to idle then using Arctic Cat Engine Storage Preserver rapidly inject 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 4 Plug the exhaust hole in the exhaust system with a clean cloth 5 Apply light oil to the upper steering post bushing and plungers o...

Page 7: ...ables 7 Check the entire brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace as necessary 8 Tighten all nuts bolts cap screws and screws mak ing sure all calibrated nuts cap screws and bolts are tightened to specifications 9 Check tire pressure Inflate to recommended pres sure as necessary 10 Make sure the steering moves freely and do...

Page 8: ...hrottle Lever Pivot B Brake Lever Pivot C Auxiliary Brake Pedal Pivot Air Filter 1 Remove the seat then remove the clips securing the air filter housing cover XR002A 2 Loosen the clamp securing the air filter to the inside of the housing then remove the filter XR029A 3 Carefully remove the pre filter from the air filter If the air filter is dirty it must be replaced XR049 4 Using an air hose clean...

Page 9: ...d loosen the jam nut then rotate the tappet adjuster screw clockwise until friction is felt C Align the valve adjuster handle with one of the marks on the valve adjuster dial D While holding the valve adjuster handle in place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in Feeler Gauge Procedure sub sec...

Page 10: ...ion 8 If compression is now evident service the piston rings see Engine Transmission Spark Plug A light brown insulator indicates that a plug is correct A white or dark insulator indicates that the engine may need to be serviced To maintain a hot strong spark keep the plug free of carbon ATV 0051 Adjust the gap to correct specification see General Infor mation for proper type and gap Use a feeler ...

Page 11: ...is changed so the oil will drain easily and completely 1 Park the ATV on level ground 2 Remove the oil level stick filler plug CF109M KC372A 3 Remove the drain plug from the bottom of the engine and drain the oil into a drain pan 733 441A 4 Using the adjustable Oil Filter Wrench and a suitable wrench remove the old oil filter NOTE Clean up any excess oil after removing the filter 5 Apply oil to a ...

Page 12: ...lecting an appro priate transmission gear can lower the temperature When filling the cooling system use a coolant water mixture which will satisfy the coldest anticipated weather conditions of the area in accordance with the coolant manufacturer s recommendations While the cooling sys tem is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut ...

Page 13: ...nstall the drain plugs and tighten securely 5 Pour recommended oil into each filler hole XR022A NOTE Arctic Cat recommends the use of genuine Arctic Cat lubricants 6 Install the filler plugs WARNING Never check the coolant level when the engine is hot or the cooling system is under pressure CAUTION After operating the ATV for the initial 5 10 minutes stop the engine allow the engine to cool down a...

Page 14: ...the circuit Troubleshoot the harness connectors gear position switch connector gear position switch and LCD connector Hydraulic Brake Systems CHECKING BLEEDING The hydraulic brake systems have been filled and bled at the factory To check and or bleed a hydraulic brake sys tem use the following procedure 1 With the master cylinder in a level position check the fluid level in the reservoir On the ha...

Page 15: ...sent XR023A NOTE During the bleeding procedure watch the reservoir very closely to make sure there is always a sufficient amount of brake fluid If low refill the reser voir 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 hyd...

Page 16: ...e to a stop 2 Accelerate to 30 mph then release the accelerator pedal and compress brake lever or apply the auxil iary brake 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 and brake pedal see St...

Page 17: ... or 165 ft lb 550 700 CF379A NOTE At this point the cap screw can be removed from the driven pulley 3 With the vehicle in neutral rotate the V belt and clutches counterclockwise until the V belt is flush with the top of the driven pulley 4 Place the CVT cover gasket into position then install the cover and secure with the cap screws Tighten the cap screws to 45 in lb 5 Install the right side footr...

Page 18: ...front rack the front body panel must be removed REMOVING 1 Remove the seat then remove the shift lever knob 2 Remove the left side engine cover then remove the fasteners securing the side panels to the frame Remove the side panels XR135A 3 Remove the torx head screws securing the center access cover to the console XR134A 4 Pry the gauge from the console then disconnect the gauge and set aside 5 Sl...

Page 19: ...until correctly positioned 8 Install the center access panel and secure to the con sole with the two torx head screws Tighten to 8 ft lb 9 Connect the gauge then press the gauge into posi tion 10 Install the side panels making sure the tabs are all correctly in the slots and the shift lever is correctly oriented then secure with the fasteners 11 Install the left side engine cover then install the ...

Page 20: ...sing the two existing torx head screws Tighten to 13 ft lb 6 Connect the taillight connectors 7 Install the side panels shift lever knob and seat LCD Gauge REMOVING INSTALLING To remove the gauge pull out on one side of it then dis connect the multi pin connector and remove the gauge XR106 To install the gauge connect the multi pin connector and press the gauge into the dash NOTE Ensure the rubber...

Page 21: ...eering post to disengage the upper coupler from the EPS assembly 9 Disconnect the 2 pin and 8 pin connectors from the top of the EPS housing EPS007A 10 Remove four cap screws securing the EPS housing to the frame then lift the assembly upward sufficiently to disengage the lower coupler and remove from the left side 11 Remove the cotter pins and slotted nuts from the inner and outer tie rod ends th...

Page 22: ...ost and secure the housings and plate to the frame with two cap screws Tighten to 20 ft lb 3 Install the tie rods and secure with the slotted nuts Tighten to 30 ft lb then install new cotter pins NOTE If the slots do not align with the holes in the tie rod ends tighten the nuts just enough to allow installation of the cotter pins AF778D 4 Install the handlebar and secure with the handlebar caps Ti...

Page 23: ...o 20 ft lb 6 Install the handlebar and secure with the handlebar caps Tighten the screws to 25 ft lb 7 Install the shock absorber and tighten to 50 ft lb 8 Install the handlebar cap then install the console and gauge Handlebar Grip REMOVING 1 Loosen but do not remove the cap screws in the end of the handlebar then tap lightly on the head to dis lodge the handlebar plug XR121 XR123A 2 Grasp the end...

Page 24: ...f of the throt tle control then remove the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm to the throttle control lever AF677D 4 Remove the actuator arm and account for a bushing Note the position of the return spring for installing purposes AF678D INSTALLING 1 Place the return spring into the throttle control then place the bushing and a...

Page 25: ...A CLEANING AND INSPECTING 1 Clean all knuckle components 2 Inspect the bearing for pits gouges rusting or pre mature wear 3 Inspect the knuckle for cracks breaks or porosity 4 Inspect threads for stripping or damage ASSEMBLING AND INSTALLING 1 Install the bearing then install the snap ring making sure it seats into the knuckle XR166A 2 Install the knuckle to the upper and lower ball joints and sec...

Page 26: ...1 Thoroughly wash the ATV to remove excess weight mud etc 2 Refer to the specifications and ensure the tires are properly inflated to the recommended pressure NOTE Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur 3 Place the ATV in a level position taking care not to push down or lift up on the front end then turn the handlebar to the straight ahead positi...

Page 27: ...ks at a height parallel to the belly panel at the front side then record the measurement 10 Push the ATV forward until the marks are parallel to the belly panel on the back side then measure the distance between the marks 11 The difference in the measurements must show 1 8 1 4 in toe out the front measurement 1 8 1 4 in more than the rear measurement 12 If the difference in the measurements is not...

Page 28: ...g the lower bumper to the frame Tighten to 35 ft lb 2 Install the two cap screws and nuts to secure the upper bumper to the mounting tabs then tighten to 20 ft lb Belly Panel REMOVING INSTALLING 1 Remove the machine screws and shoulder washers securing the belly panel to the underside of the frame then remove the belly panel 2 Place the belly panel into position on the underside of the frame then ...

Page 29: ... to the wiring harness and insert into headlight assembly Turn clockwise to secure the bulb NOTE On the Limited models the headlight is a non serviceable component it must be replaced as an assembly 1 Disconnect the wiring harness connector A remove the headlight adjustment screw and release the clips then remove the headlight assembly XR161A 2 Install the new headlight assembly secure with clips ...

Page 30: ...vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights 5 Switch on the lights Make sure the HIGH beam is on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when the most intense beam is centered on the verti cal mark 5 cm 2 in below the horizontal mark on the aiming surface 7 To adjust the headlights loosen the adjustment k...

Page 31: ...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 32: ...the customer to follow the proper break in procedure as described in the Operators Manual 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 Department Description p n Clutch Sleeve...

Page 33: ...meter max 20 021 mm Connecting Rod big end side to side 0 7 mm Connecting Rod small end deflection max 3 0 mm Crankshaft web to web 60 8 60 9 mm Crankshaft Runout max 0 03 mm VALVES AND GUIDES Valve Face Diameter max intake exhaust 31 6 mm 27 9 mm Valve Tappet Clearance intake cold engine max exhaust 0 1016 mm 0 1524 mm Valve Guide Stem Clearance max 0 013 mm Valve Guide Inside Diameter 5 000 5 01...

Page 34: ...Fuel injector obstructed 6 Valve clearance out of adjustment 1 Drain gas replace with clean gas 2 Clean plug 3 Replace magneto 4 Replace ECM 5 Replace fuel injector 6 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 Repl...

Page 35: ...ition Remedy 1 Gasoline bad contaminated 2 Engine oil overfilled contaminated 3 Piston rings cylinder worn 4 Valve guides worn 5 Cylinder wall scored 6 Valve stems worn 7 Stem seals defective 1 Drain gas replace with clean gas 2 Drain excess oil replace oil 3 Replace service rings cylinder 4 Replace guides 5 Replace service cylinder 6 Replace valves 7 Replace seals Problem Engine lacks power Condi...

Page 36: ...hen remove the spark plug cap from the spark plug 9 Disconnect the crankcase breather hose from the air filter housing and remove the air filter assembly 10 From the left side disconnect the following items A Stator Connector B Crankshaft Position Sensor Connector C Engine Coolant Temperature Sensor Connector D Fuel Hose E TPS Connector F MAP IAT Sensor Connector G ISC Connector H Fuel Injector Co...

Page 37: ...end of the exhaust pipe Discard the seals 17 On the 550 700 remove outer coolant hose from the water pump then remove the coolant hose from the thermostat housing On the 500 remove the upper and lower coolant hose from the water pump then remove the coolant hose from the cylinder head XR151 XR157 XR162A 18 Remove the four cap screws securing the output shaft to the rear gear case flange then remov...

Page 38: ...der Head Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appropriate wrench rotate the crankshaft to top dead center of the compression stroke NOTE Arctic Cat recommends the use of new gaskets lock nuts and seals and lubricating all internal components when servicing the engine transmission 1 Remove the cap screws s...

Page 39: ...wn into the crankcase MD1131 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 FI620 FI617A 7 Remove the cam chain tensioner pivot bolt and remove the chai...

Page 40: ...the cylinder remove the gasket and account for two alignment pins FI623A 10 Remove the cam chain guide FI621 C Cylinder D Piston NOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the two nuts securing the right side of the cylinder to the right side crankcase half AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section AT THI...

Page 41: ...ms 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 cylinder head cover cannot be trued the cylinder head assembly must be replaced 1 Wash the cylinder head cover in parts cleaning sol vent AT THIS POINT To service cylinder see Servicing Top Side Comp...

Page 42: ...r head and remove the valves Measuring Valve Guide Bore 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 Guides Valve Seats If valves valve guides or valve seats require ...

Page 43: ...he perimeter of each piston for signs of blowby indicated by dark discoloration Blowby is caused by worn piston rings excessive 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 Remove each ring by working it toward the top of the piston while rotating it out of the groove NOTE When instal...

Page 44: ...ence clearance must be within specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap...

Page 45: ... 3 Place the cylinder on the surface plate covered with 400 grit wet or dry sandpaper Using light pressure move the cylinder 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 continu ing to move the cylinder in a figure eight motion until a uniform bright metallic fini...

Page 46: ... the dial indicator contact point against the shaft and zero the indicator CC283D 2 Rotate the camshaft and note runout maximum tol erance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe height ATV1013A 2 The lobe heights must be greater than minimum specifications Inspecting Camshaft Bearing Journal 1 Inspect the bearing journal for scoring s...

Page 47: ...stitute beneath the piston skirt and square the piston in respect to the crankcase MD1344 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers 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 GZ142 4 Loosely install th...

Page 48: ...ts 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 to the front install the rear cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer Tighten to 11 ft lb CD383 12 With the alignment pin installed in the camshaft and the cam lo...

Page 49: ... 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 16 Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole MD1363 17 Apply red Loctite 271 to the first cap screw secur ing t...

Page 50: ...lve cover then place the valve cover into position Note that the two alignment pins are properly positioned NOTE At this point the rocker arms and adjuster screws must not have pressure on them 25 Install the four top side cap screws with rubber washers then install the remaining cap screws Tighten only until snug MD1261 26 In a crisscross pattern starting from the center and working outward tight...

Page 51: ...r two crush washers and an O ring FI544 4 Remove the water pump drive gear then remove the speed sensor housing assembly Account for two alignment pins a gasket and two seal washers FI543 5 Remove the cap screws securing the magneto cover to the crankcase Note the location of the two inter nal cap screws and the two longer cap screws FI596A 6 Remove the magneto cover and account for two alignment ...

Page 52: ...e the starter motor Account for an O ring on the starter drive housing FI555 G Shift Shaft H Drive Gear NOTE Steps 1 10 in the preceding sub sections must precede this procedure 11 Remove the shift shaft noting a washer on each end then remove the cap screw securing the gear shift cam plate and remove the plate from the shaft FI559 12 Remove the shift detent cam arm and spring FI560 13 Remove the ...

Page 53: ...oose 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 the starter clutch assembly FI572 REPLACING STARTER CLUTCH ASSEMBLY 1 Remove the cap screws securing the starter clutch assembly to the flywheel then remove from the fly wheel FI570 2 Thoroug...

Page 54: ...g bores 3 Inspect the oil pressure relief valve for evidence of metal chips or contamination Do not disassemble the valve FI588 REPLACING STATOR COIL CRANKSHAFT POSITION SENSOR 1 Remove the three cap screws securing the stator coil two cap screws securing the crankshaft position sen sor and one cap screw from the harness hold down 2 Lift the rubber grommet out of the housing then remove the stator...

Page 55: ... a new bearing into the magneto cover until the bearing is firmly seated in the bearing bore Installing Left Side Components A Starter Clutch Gear B Rotor Flywheel 1 If removed 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 10 ft ...

Page 56: ...cede this procedure 9 Install two alignment pins and place the magneto cover gasket into position Install the magneto cover Noting the different lengthed 6 mm cap screws and the location of the two internal cap screws tighten the cap screws in a crisscross pattern to 8 ft lb FI596A 10 Install the water pump drive gear and secure with the nut Tighten to 28 ft lb FI547 11 Install two alignment pins ...

Page 57: ...l in the frame remove the cap screw securing the brake pedal to the pedal axle Account for a flat washer KC149A 2 Remove the cap screws securing the V belt cover to the clutch cover then slide the brake pedal outward and remove the V belt cover Account for two align ment pins and a gasket KC142A 3 Mark the movable drive face and the fixed drive face for installing purposes then remove the nut hold...

Page 58: ...he 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 9 Remove the cap screws holding the clutch cover onto the right side crankcase half Note the positions of the different lengthed cap screws for installing pur poses 10 Using a rubber mallet loosen the clutch cover then pull it awa...

Page 59: ...een 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 FI630 14 Remove the oil pump drive gear cap screw MD1018 15 Remove oil pump drive gear Account for the pin MD1017 16 Remove the snap ring holding the oil pump driven gear CAUTION Care must be taken when removing the nut it ha...

Page 60: ...nment pins MD1060 19 Remove the four cap screws securing the oil strainer cap then remove the Phillips head screws securing the oil strainer Account for the O ring MD1337 MD1208 Servicing Right Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE Inspect the clutch shoe for uneven wear chips cracks or discoloration If wear is present replace the clutch assembly ATV1014 AT THIS POINT To service clutc...

Page 61: ...locks up or turns in both directions 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 must be replaced as a complete assem bly DRIVEN PULLEY ASSEMBLY NOTE The driven pulley assembly is a non...

Page 62: ...p 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 crankcase boss 6 Place the pin into position install the oil pump drive gear and tighten the cap screw coated with red Loc tite 271 to 63 ft lb MD1017 MD1018 7 Install the clutch shoe assembly on the crankshaft then install the flange nut left hand thread ...

Page 63: ...screws to 8 ft lb MD1117 11 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 12 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 13 Slide the fixed drive face assembly onto the front shaft 14 Spread the faces of ...

Page 64: ...te the V belt and drive driven assemblies until the V belt is flush with the top of the driven pulley 18 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 19 If removed install the brake pedal and tighten to 25 ft lb Center Crankcase Components NOTE This procedure cannot be done with the eng...

Page 65: ...Account for two alignment pins CC869 NOTE To keep the shaft gear assemblies intact for identification tap the shafts toward the left side crankcase half when separating the halves MD1313 Disassembling Crankcase Half NOTE To aid in installing it is recommended that the assemblies be kept together and in order NOTE For steps 1 6 refer to illustration FI639A FI639A 1 Remove the secondary driven shaft...

Page 66: ... 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 disengage from the gear shift shaft F FI646 FI653A 4 Remove the gear shift shaft F noting the inner and outer washers FI650A 5 Remove the countershaft assembly E along with the shift fork assembly FI662 ...

Page 67: ...lash NOTE If backlash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove measure and install until backlash measurement is within t...

Page 68: ...aximum diameter must not exceed specifications Measuring Connecting Rod Small End Deflection 1 Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate Posi tion the indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the small end of the con necting rod away from the dial indicator 3 Maximum def...

Page 69: ...from the out side edge of one web to the outside edge of the other web H1 006 2 Acceptable width range must be within specifica tions COUNTERSHAFT Disassembling 1 Remove the reverse driven gear dog then remove the circlip securing the reverse driven gear FI663 FI664 2 Remove the splined washer then remove the reverse driven gear along with the bearing and bushing CAUTION Care should be taken to su...

Page 70: ... Remove the slid ing dog FI668 FI669 5 Remove the circlip securing the high driven gear then remove a washer the high driven gear along with the bearing and bushing and remove the high driven washer FI670 FI671 ASSEMBLING 1 With the high driven washer 1 on the countershaft install the high driven gear bushing 3 bearings 2 and gear 4 on the countershaft then install the washers 5 and secure with th...

Page 71: ...ow driven bushing 10 bearing 9 and gear 11 on the countershaft then install splined washer 12 FI667A FI666 4 Place the reverse driven bushing 13 onto the shaft then install the bearing 14 gear 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 ...

Page 72: ...en the output shaft flange nut to 59 ft lb Using a punch peen the nut MD1333 3 Apply a liberal amount of oil to the crankshaft bear ing Using a propane torch heat the bearing until the oil begins to smoke then slide the crankshaft assem bly 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 count...

Page 73: ...ition on the assembled countershaft and install into the crankshaft as 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 ...

Page 74: ...r suitable substitute sealant to the mating surfaces Place the right side half onto the left side half FI639B NOTE Be sure to apply silicone to the inside radius of all cap screw locations and the entire surface of the internal cap screw bosses FI639D 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 scre...

Page 75: ...crews until the halves are correctly joined then tighten to 21 ft lb NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs 6 In a crisscross pattern tighten the 6 mm cap screws to 10 ft lb NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs AT THIS POINT After completing center crankcase components pro ceed to Installing Right Side Components to In...

Page 76: ... engine transmission does not have to removed from the frame for this procedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug and timing inspection plug then using a socket and ratchet rotate the crank shaft to top dead center of the compression stroke 1 Remove the two tappet covers CC001D NOTE Keep the mounting hardware with the covers ...

Page 77: ...C ring down into the crankcase CC012D 7 Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft then drop the sprocket off the camshaft CC013D 8 While holding the chain slide the sprocket and cam shaft out of the cylinder head NOTE Loop the chain over the cylinder and secure it to keep it from falling into the crankcase FI620 9 Remove the cap screw securing th...

Page 78: ...ion must precede this procedure 13 Loosen the clamp securing the coolant hose to the union then detach the hose 14 Remove the two nuts securing the cylinder to the crankcase CC023D 15 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 AT THIS POINT To service valves and cylinder head see Servicing Top ...

Page 79: ...he piston rings must be removed remove them in this sequence A Starting with the top ring slide one end of the ring out of the ring groove B Remove each ring by working it toward the dome of the piston while rotating it out of the groove AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub section CAUTION When removing the cylinder be sure to support the pis ton to prevent dama...

Page 80: ...or compress the valve springs and remove the valve cotters Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC136D NOTE The valve seals must be replaced 3 Remove the valve springs then invert the cylinder head and remove the valves Measuring Valve Guide Bore 1 Insert a snap gauge 1 2 way down into each valve guide bore t...

Page 81: ...izure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or honing oil NOTE If scuffing or seizure marks are too deep to correct with the sandpaper replace the piston 3 Inspect the perimeter of each piston for signs of excessive blowby Excessive blowby indicates worn piston rings or an out of round cylinder Removing Piston Rings 1 Starting with the top ring slide one end of the ...

Page 82: ...bove the piston skirt at a right angle to the piston pin bore Subtract this measure ment from the measurement in step 1 The difference clearance must not exceed specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lowe...

Page 83: ...a feeler gauge check the distortion factor between the head and the straightedge 3 Maximum distortion must not exceed specifications CC141D Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting scoring scuffing warpage and corrosion If marks are found repair the surface using a cylinder hone see Inspecting Cylinder in this sub section 3 Place...

Page 84: ... hone NOTE To produce 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 I...

Page 85: ...oward the exhaust CC032D 2 Place the two alignment pins into position Place the cylinder gasket into position then place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase CF083 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Route the cam...

Page 86: ...y until snug CC272D 9 Loosely install the five cylinder head nuts 10 Using a crisscross pattern tighten the four cap screws from step 8 initially to 20 ft lb then in 10 ft lb increments tighten to a final torque of 40 ft lb 11 Tighten the 8 mm nuts from step 9 to 21 ft lb and the 6 mm nuts to 8 5 ft lb then tighten the two cylin der to crankcase nuts from step 4 securely 12 With the timing inspect...

Page 87: ...m sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket then place the camshaft sprocket assembly onto the cylinder ensuring the following CF013A A Piston still at top dead center B Camshaft lobes directed down toward the pis ton C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket dir...

Page 88: ...der head CC012D 22 Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside CD468 23 Remove the cap screw from the end of the chain ten sioner then using a flat blade screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the ten sioner as the adjuster screw is ...

Page 89: ... of the cylinder head and valve cover CC275D 28 Place the valve cover into position NOTE At this point the rocker arms and adjuster screws must not have pressure on them 29 Install the four top side cap screws with rubber wash ers then install the remaining cap screws Tighten only until snug CC003D 30 In a crisscross pattern starting from the center and working outward tighten the cap screws from ...

Page 90: ...aft to aid in installing then remove the shift arm FI085A 4 Remove the cap screws securing the speed sensor housing to the crankcase and remove the housing assembly then remove the snap ring securing the speed sensor trigger to the shaft and remove the trig ger Account for the gasket NOTE It may be necessary to use a small two jaw puller to remove the trigger CD920 GZ254 5 Loosen the clamps securi...

Page 91: ...0A 11 Remove the two starter gears from the crankcase not ing the direction of the beveled side of the gears for installing purposes then remove the two starter gear shafts CD136 CD140 12 Remove the snap ring securing the water pump drive gear then remove the gear noting the direction of the sides of the gear for installing purposes Account for the drive gear alignment pin CD944 13 Remove the snap...

Page 92: ...tch gear onto the rotor flywheel and attempt to rotate the starter clutch gear clock wise It should lock up to the rotor flywheel Rotate the gear counterclockwise and it should turn freely If it moves or locks 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 w...

Page 93: ... Loctite 620 to the bearing outer race and press into the gear hub until even with the lower chamfer radius FI580 INSPECTING STATOR COIL MAGNETO COVER ASSEMBLY 1 Inspect the stator coil for burned or discolored wir ing broken or missing hold down clips or loose cap screws 2 Inspect the bearings in the magneto housing for dis coloration roughness when rotated and secure fit in bearing bores REPLACI...

Page 94: ...mponents NOTE Plug the oil passage in the crankcase hous ing prior to installing the drive gear driven gear assembly to prevent loss of an alignment pin 1 Install the water pump driven gear alignment pin and the driven gear with the beveled side of the gear fac ing outward as noted in removing then secure with the snap ring CD950A CD952A CD949 NOTE The sharp side of the snap ring should be facing ...

Page 95: ...ng CD139 PR447A 4 In order on the crankshaft install a washer ring gear key and the magneto rotor Secure with the nut Tighten to 107 ft lb CD948A CD940B 5 Install the thrust washer and shift cam plate onto the shift cam shaft then coat the cap screw threads with red Loctite 271 and tighten to 8 ft lb PR433A CD934 6 Install the shift cam stopper spring and two washers thick washer closest to the nu...

Page 96: ...ith the cap screws Tighten only until snug 10 Place the bushing into position on the crankshaft making sure a new lubricated O ring is inside the bushing Tighten the flange nut to 25 ft lb 11 Using a crisscross pattern tighten the cap screws from step 9 to 8 ft lb 12 Clean the countershaft and trigger splines thoroughly and install the inner snap ring onto the shaft then apply green Loctite 620 to...

Page 97: ...le to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine 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 D Oil Pump 1 Remove the cap screws securing the CVT cover the...

Page 98: ...in installing it is recommended that the assemblies are kept together and IN ORDER CC829B 7 Remove the one way clutch D from the clutch housing Note the location of the green alignment dot or the word OUTSIDE for installing purposes 8 Using a hydraulic press remove the clutch housing assembly from the clutch cover Account for the left fixed drive spacer and an O ring inside the fixed drive spacer ...

Page 99: ...move the nut left hand threads securing the clutch shoe assembly C PR410A 11 Remove the cap screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer CC606 CD987 CD993 12 Using an impact wrench remove the cap screws securing the final drive carrier bearing housing E then remove the housing and account for two align ment pins CD999 ...

Page 100: ...clutch shoes for wear or damage If any shoe is worn to the bottom of the groove replace the clutch assembly ATV1014 INSPECTING CLUTCH HOUSING 1 Inspect the clutch housing for burns grooving cracks or uneven wear 2 If the housing is damaged in any way the housing must be replaced INSPECTING PRIMARY ONE WAY DRIVE 1 Insert the drive into the clutch housing 2 Rotate the inner race by hand and verify t...

Page 101: ... Install the oil pump onto the engine then tighten the screws coated with red Loctite 271 to 8 ft lb CD988 4 Install the oil pump drive gear spacer onto the crank balancer shaft Grease the pin and insert it into the shaft then install the drive gear making sure the raised side of the gear is facing toward the inside Secure the gear with the cap screw threads coated with red Loctite 271 and the was...

Page 102: ...clutch onto the clutch shoe assembly PR399A 9 Lightly grease the clutch housing seal then insert the left fixed drive spacer CF088A CF085A 10 Apply grease to the outer edges of the clutch hous ing then from inside the clutch cover install the clutch housing into the cover using a rubber mallet 11 Place the clutch cover housing assembly into posi tion on the crankcase then secure with the cap screw...

Page 103: ...the driven pulley and over the front shaft GZ085 NOTE The arrows on the V belt should point in the direction of rotation 17 Pinch the V belt together near its center and slide the spacer and movable drive face onto the front shaft Secure the drive face with a washer and nut coated with red Loctite 271 Using an appropriate spanner wrench tighten the nut to 147 ft lb 500 or 165 ft lb 550 700 CF379 N...

Page 104: ...screws 2 Remove the left side cap screws securing the crank case halves Note the location of the differ ent lengthed cap screws 3 Using the Crankcase Separator Crankshaft Remover and tapping lightly with a rubber mallet separate the crankcase halves Account for two alignment pins NOTE To keep the shaft gear assemblies intact for identification tap the shafts toward the left side crankcase half whe...

Page 105: ...he crankcase to remove the driveshaft CC675 7 Note the timing marks on the crank balancer assem bly B gear and crankshaft C gear for assembling purposes then slide the crank balancer gear off the crank balancer Account for the key in the keyway CD826 8 Remove the crank balancer NOTE There is a flat spot on the crank balancer bearing flange to allow clearance past the crankshaft CD832B 9 Remove the...

Page 106: ...driven gear is replaced proceed to Correcting Backlash in this sub section 1 Install a new bearing A onto the secondary driven shaft B making sure the bearing locating groove is directed away from the driven gear splines MT011A 2 Using a suitable press install the driven gear C on the shaft until the gear firmly seats on the shoulder of the shaft MT011B 3 If installing the existing shaft start wit...

Page 107: ...eading on the gauge MT005A 5 Acceptable backlash range is 0 127 0 381 mm 0 005 0 015 in Correcting Backlash NOTE If backlash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and in...

Page 108: ...o 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 not exceed specifica tions Measuring Crankshaft Runout 1 Place the crankshaft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the indicator contact at point 1 of the crank shaft H1 003 3 Zero the indica...

Page 109: ...ft GZ296 GZ312 3 Remove the reverse driven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer then remove the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer GZ320 CAUTION When disassembling the countershaft care must be taken to note the direction each major component dog gear faces If a major component is ins...

Page 110: ...om the drive gear end install a thrust washer bushing and bearing then install the low driven gear and washer GZ317A GZ318 2 Install the low driven gear locking washer then install the inner reverse driven gear washer GZ319B GZ320B 3 Install the reverse driven bushing and bearing then install the reverse driven gear ...

Page 111: ...e opposite end of the countershaft install the high low driven gear dog A thrust washer B bushing C bearing D high low driven gear E and spacer washer F GZ283B 7 Install the two drive gear washers and the shift forks The countershaft is now ready for installation NOTE When installing the countershaft assembly account for the washer on each end of the shaft Assembling Crankcase Half 1 Install the s...

Page 112: ...nk balancer CD832B NOTE It will be necessary to rotate the crank bal ancer until the counterweight is facing away from the crankshaft then rotate the crankshaft clockwise into the journal area to allow the crank balancer to be fully seated 4 Place the key into the crank balancer keyway then install the crank balancer gear making sure the align ment dots on the crank balancer gear and the crank sha...

Page 113: ...p of the crankcase and the bearing C ring is fully seated in the crankcase PR787B 11 Place the oil strainer into position then secure with the two screws 12 Place the oil strainer cap into position making sure silicone sealant is applied then secure the cap with cap screws Tighten to 10 ft lb Joining Crankcase Halves 1 Apply High Temp Sealant to the left side mating surface smoothing out any build...

Page 114: ...ame rear of engine first tilting the rear up to allow the cylinder head to clear frame 2 Install the two through bolts Secure with lock nuts and tighten to 35 ft lb 3 Install output shafts to the front differential and rear gear case flanges and tighten to 20 ft lb 4 On the 550 700 connect the coolant hose to the water pump and connect the coolant hose to the ther mostat housing On the 500 connect...

Page 115: ...2 Connect the air ducts to the CVT housing and tighten the clamps securely then connect the air inlet tube to the air filter housing and the throttle body and secure with the clamps XR137B 13 Install the front body panel and footwells and con nect the battery positive cable first 14 Pour the specified amount of coolant into the radiator and the specified amount and grade of oil into the engine 15 ...

Page 116: ...e actuator cover to the throttle body then remove the cover XR129A 5 Remove the throttle cable from the actuator arm 6 Loosen the outer jam nut securing the throttle cable to the throttle body then route the cable out of the way 7 Remove the MAP sensor fuel injector connector ISC connector and TPS connector 8 Loosen the clamp securing the air filter housing boot to the throttle body inlet then rem...

Page 117: ...r 10 seconds 3 Release the accelerator pedal and wait an additional 10 seconds 4 Turn the key to the OFF position and allow the gauge to shut off Throttle Cable Free Play To adjust the throttle cable free play follow this proce dure 1 Slide the rubber boot away then loosen the jam nut from the throttle cable adjuster CF297A 2 Turn the adjuster until the throttle cable has proper free play of 3 6 m...

Page 118: ...r mounting bracket to the frame then secure the master cylinder to the mount ing bracket Tighten the master cylinder nut to 12 ft lb NOTE Ensure the tab of the mounting bracket is in place on the gas tank 3 Secure the vent hose to the frame with cable ties as noted during removing then connect the gasline hose and fuel pump connector 4 Secure the gas tank mounting tab to the frame using the existi...

Page 119: ... the frame then install the cap screws and nuts Tighten to 12 ft lb 3 Install the upper and lower coolant hoses then secure with hose clamps AF734D 4 Install the front body panel rack 5 Fill the cooling system with the recommended amount of antifreeze see Periodic Maintenance Check for leakage 6 Connect the fan wiring to the main wiring harness THERMOSTAT Removing 1 Drain approximately one quart o...

Page 120: ...Loosen the hose clamps and slide the clamps away from the hose ends approximately 2 in then remove both hoses from the water pump 5 Using an impact driver loosen but do not remove the two Phillips head cover screws XR151B 6 Remove the two cap screws securing the water pump to the engine then remove the water pump XR151C Installing 1 Secure the water pump to the engine with the two cap screws tight...

Page 121: ...tion Remedy 1 Gas contaminated 2 TPS out of adjustment 3 Air filter housing contaminated 1 Drain gas tank and fill with clean gas 2 Adjust TPS 3 Clean or replace air filter housing or replace Problem Medium or high speed impaired Condition Remedy 1 Gas contaminated 2 High RPM cut out against RPM limiter 3 Air filter housing contaminated 1 Drain gas tank and fill with clean gas 2 Decrease RPM speed...

Page 122: ...autions provided with the battery or battery maintainer charger Loss of battery charge may be caused by ambient temper ature ignition OFF current draw corroded terminals self discharge frequent start stops and short engine run times Frequent winch usage snowplowing extended low RPM operation short trips and high amperage accessory usage are also reasons for battery discharge Maintenance Charging N...

Page 123: ...he left side of the charger select the Normal Charge Icon E The Normal Charge Indicator C should illuminate on the upper left portion of the charger 6 The battery will charge to 95 of its capacity at which time the Maintenance Charge Indicator D will illuminate NOTE For optimal charge and performance leave the charger connected to the battery for a minimum 1 hour after the Maintenance Charge Indic...

Page 124: ...r or inaccurate readings will occur Use wire holders to suspend the sensor and thermometer 3 On the ECT sensor when the temperature reaches 20 C 68 F the meter should read approximately 2 45k ohms 4 On the ECT sensor when the temperature reaches 50 C 122 F the meter should read approximately 800 ohms 5 On the ECT sensor when the temperature reaches 80 C 176 F the meter should read approximately 31...

Page 125: ...pen replace the fuse NOTE Make sure the fuses are returned to their proper position according to amperage Refer to the fuse block decal for fuse placement RELAYS The 4 pin relays are identical plug in type Relay func tion can be checked by switching relay positions The relays are interchangeable NOTE The module and wiring harness are not a service able components and must be replaced as an assembl...

Page 126: ... to one white wire pin then con nect the red positive test lead to the other white wire pin 3 With the meter in the OHMS position the reading should be between 6 7 10 1 ohms NOTE If the meter does not read as specified replace sensor MANIFOLD ABSOLUTE PRESSURE INLET AIR TEMPERATURE MAP IAT SENSOR NOTE Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge ...

Page 127: ...ng procedure 1 Disconnect the three wire connector from the speed sensor harness or from the speed sensor then remove the Allen head cap screw securing the sensor to the sensor housing 2 Remove the sensor from the sensor housing account ing for an O ring 3 Install the new speed sensor into the housing with new O ring lightly coated with multi purpose grease then secure the sensor with the Allen he...

Page 128: ...ecover when the bat tery supply returns to normal C1308 Temperature Above 110 C EPS internal 110o C over temp condi tion has been detected Clean the EPS housing and cooling fins EPS will auto recover when internal temperature drops below 105 C C1309 Temperature Above 120 C EPS internal 120o C over temp condi tion has been detected Clean the EPS housing and cooling fins EPS will auto recover when i...

Page 129: ... C1322 Engine RPM Lost Engine RPM signal received by the EPS exceeds 500 RPM and then is zero or missing Handlebar switch in the OFF position bro ken main harness RPM wires defect voltage regulator broken ACG stator wires EPS will auto recover when engine RPM signal returns to normal C1323 EPS OFF Gauge Dis play Battery power has been applied to the EPS for more than 5 minutes but no engine RPM si...

Page 130: ... OHMS position 2 Connect the red tester lead to the blue wire then con nect the black tester lead to the brown black wire 3 With the dimmer switch in the HI position the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance replace the switch RESISTANCE LO Beam 1 Connect the red tester lead to the white wire then connect the black tester lead to the brown black wir...

Page 131: ...w as specified replace the drive select switch Front Differential Actuator System NOTE With the engine stopped and the ignition switch in the ON position a momentary whirring sound must be noticeable each time the drive select switch is moved between positions The LCD gauge will display 4WD and 4WD Lock in the corresponding switch positions Test the switch 30 amp fuse and wiring connections prior ...

Page 132: ...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 XR117 NOTE Make sure that the ignition switch is in the ON position transmission in neutral brake lock released and the engine stop switch in the RUN position 3 Depress the starter button while observing the multi meter The multimeter should ...

Page 133: ...n install the starter motor into the crankcase Secure 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 Electronic Control Module ECM The electronic control module ECM is located beneath the seat near the battery NOTE The ECM is not a serviceable component If the unit is defective it must be replaced Th...

Page 134: ...ct the gasline hose and fuel pump connec tors 2 Remove the screws securing the fuel pump to the gas tank then make a reference mark on the fuel pump and tank 3 Lift out the fuel pump assembly then guide the pump and float lever through the opening in the gas tank 4 Using duct tape or other suitable means cover the fuel pump opening INSPECTING 1 Inspect the fuel screen and blow clean with low pres ...

Page 135: ...g ulator is faulty or a battery connection is loose or corroded Clean and tighten battery connections or replace the regulator rectifier If voltage does not rise see Stator Coil Crankshaft Position CKP Sensor Voltage in this section If charging coil voltage is nor mal replace the regulator rectifier Headlights VOLTAGE NOTE Perform this test in turn on the main harness side of all four connectors A...

Page 136: ... three wire connector from the sensor then select DC Voltage on the multimeter and con nect the red tester lead to the orange wire C and the black tester lead to the pink black wire A CD706A 2 Turn the ignition switch to the ON position The multimeter should read battery voltage If battery voltage is not indicated check the 30 amp main and 10 amp ignition fuses wiring harness or the ignition switc...

Page 137: ...on Sensor TPS NOTE Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge see EFI Diagnostic System in this section TESTING 1 On the 500 remove the left side engine cover then disconnect the three wire TPS connector plug KC517 NOTE Prior to testing the TPS inspect the three wire plug connector on the main harness and the three pin plug on the TPS for conta...

Page 138: ...ace the ignition key in the ON position and wait for 10 seconds 3 Release the accelerator pedal and wait an additional 10 seconds 4 Turn the key to the OFF position and allow the gauge to shut off TESTING 1 On the 550 700 remove the seat side covers front rack and front body panel see Steering Frame Con trols then remove the air filter assembly Remove the TPS connector plug from the TPS PR544 CF32...

Page 139: ...ter diagnostic mode cycle the display by pressing either the left or right button to step to the desired function NOTE The gauge can be utilized dynamically engine running vehicle moving or statically engine vehicle stopped DIAGNOSTIC MODES Battery BATTERY WT540 Display System DC voltage DTC P0562 P0563 P2531 P2532 Usage Verify system voltage under following condi tions 1 Battery voltage with engi...

Page 140: ...Temperature INTAKE WT592 Display Inlet air temperature in Fahrenheit or Celsius DTC P0112 P0113 P0114 Usage Verify correct output of IAT sensor NOTE After engine has been running IAT readings will be higher than outside air temperature due to engine and engine compartment heat as well as intake manifold heating MAP AIR PRESS WT602 Display MAP in millibars and in Hg DTC P0107 P0108 Usage Verify bar...

Page 141: ...erify speedometer sensor signal from the fol lowing 1 Speed sensor to ECM 2 ECM CAN signal to gauge speedometer odome ter 3 ECM CAN signal to EPS DIAGNOSTIC TROUBLE CODES DTC If an EFI or related chassis component fails or an out of tolerance signal is detected by the ECM a diagnos tic trouble code DTC will be generated in the ECM and displayed on the LCD The DTC will be displayed alter nately wit...

Page 142: ...ct harness shorted to battery power Correct condition P0263 Rear Cylinder Fuel injector Balance Open Injector has been disconnected or interconnect harness open Correct condition P0264 Front Cylinder Fuel injector Circuit Low SG Injector or interconnect harness shorted to chassis ground Correct condition P0265 Front Cylinder Fuel injector Circuit High Injector or interconnect harness shorted to ba...

Page 143: ... Circuit High Coil or interconnect harness shorted to battery power Correct condition P2303 Front Ignition Coil Primary Circuit Low Open Coil or interconnect harness open or shorted to chassis ground Correct condition P2304 Front Ignition Coil Primary Circuit High Coil or interconnect harness shorted to battery power Correct condition P2531 Ignition Switch Circuit Low Battery charge condition low ...

Page 144: ...tor rectifier 4 Replace battery Problem Battery overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier resistor damaged defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace resistor 3 Clean tighten ground connection Problem Charging unstable Condition Remedy 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier ...

Page 145: ...ed REMOVING 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 XR165A 3 Remove the mounting cap screw from below the actuator on the suspension side XR163A 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 mou...

Page 146: ...he wiring harness to the frame with a nylon cable tie Front Differential 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 brake then engage the brake lever lock 5 Remove and discard the cotter pins...

Page 147: ...nd account for the A arm brace XR170 14 Push the axle shaft firmly toward the differential to release the internal lock then while holding the axle in pull the CV cup from the differential NOTE Keeping the axle level will aid in removal CF633A 15 Using a T 30 torx wrench remove the three screws securing the front drive actuator to the gear case then remove the actuator 16 Remove the lower differen...

Page 148: ...may vary from model to model The technician should use dis cretion and sound judgment 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing GC004A 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for assem bling purposes GC015 CD106 3 Using a boot clamp pliers or suitable substitute remo...

Page 149: ... pinion housing in a press and remove the bearing GC011 AF984 KX219 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside GC012 GC011 2 Install the input shaft seal making sure it is fully seated in the housing ...

Page 150: ...stall the front boot and secure with an appropriate boot clamp and the rear boot with an appropriate boot clamp CD112 CD099A 5 Place the pinion housing with new gasket onto the differential housing then secure with the existing cap screws Tighten to 23 ft lb existing housing or 28 ft lb new housing CD103 Disassembling Differential Assembly NOTE This procedure can be performed on a rear gear case 1...

Page 151: ...position of parts for assembling purposes KX175 5 Remove the left differential bearing flange assembly and account for a shim Mark the shim as left side KX177 KX178 6 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s and mark as right side KX179 KX181 Disassembling Pinion Gear 1 Remove the internal snap ring securing the pinion bearing ...

Page 152: ...le parts from the gear case hous ing then discard the housing and lock collar Assembling Pinion Gear 1 Install the bearing onto the pinion shaft Install the pinion shaft collar CC882 CC883 2 Place the pinion assembly in a bearing puller then install the bearing using a press CC884 3 Using a propane torch heat the gear case housing to approximately 200 F then install the pinion assem bly 4 Install ...

Page 153: ... 055 in shim on the gear case side of the ring gear assembly GC031A 2 Install the ring gear with shim in the gear case then while holding the pinion stationary rock the ring gear forward and back to determine if any backlash exists If no backlash exists install a thicker shim and recheck GC036A 3 Install the bearing flange onto the gear case cover making sure the alignment locating pin engages the...

Page 154: ...g 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 backlash NOTE Higher backlash settings usually result in quieter gear operation GC0...

Page 155: ...e selected end play shim chamfered side toward the gear onto the cover side of the ring gear GC036B NOTE The spider and ring gear assembly must be replaced as a complete unit 3 Assemble the fork and sliding collar into the cover assembly then install the left bearing flange bearing assembly and seat firmly into the cover CF266A CF267A 4 Apply a liberal coat of grease to the O ring then install it ...

Page 156: ...ews Tighten to 23 ft lb existing housing or 28 ft lb new housing CD103 CD110 Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool CC899 NOTE Prior to installing the seal apply High Per formance 2 Molybdenum Disulphide grease to the seal outside diameter 2 Using Gear Case Seal Installer Tool evenly press the seal into the...

Page 157: ...ws then connect the wire connec tor to the main wiring harness 5 Install the front axles see Drive Axles in this sec tion 6 Secure the upper A arms with cap screws and new lock nuts Tighten to 50 ft lb XR152A 7 Secure the lower shock eyelets with cap screws and lock nuts Tighten to 50 ft lb 8 Secure the hub assembly to the shaft axle with the nut Tighten only until snug at this point 9 Secure the ...

Page 158: ...while holding the axle in pull the CV cup from the gear case NOTE Keeping the axle level will aid in removal CF633A REMOVING FRONT DRIVE AXLE NOTE For removing a front drive axle see Front Differential in this section CLEANING AND INSPECTING NOTE Always clean and inspect the drive axle com ponents to determine if any service or replacement is necessary 1 Using a clean towel wipe away any oil or gr...

Page 159: ... NOTE In the outboard boot use the final 40 grams 1 3 of contents of grease from the pack in the bear ing housing INSTALLING REAR DRIVE AXLE 1 Push the axle shaft into the CV cup to release the detent balls then while holding the axle firmly in push the CV splined end into the gear case CF633A NOTE To assure proper seating of the axle give it a light pull the axle should remain clipped in place 2 ...

Page 160: ...n in the steer ing knuckle followed by a washer and hex nut Tighten finger tight at this time 5 Install the brake caliper on the steering knuckle using new patch lock cap screws Tighten to 20 ft lb then pump up the hand brake lever and engage the brake lever lock 6 Using an appropriate spanner wrench tighten the hub nut from step 4 to 200 ft lb then install and spread a new cotter pin making sure ...

Page 161: ...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 the threads and tighten to 8 ft lb left hand threads 4 If clearance is not as specified repeat steps ...

Page 162: ...12A 6 Using an appropriate hub retaining wrench tighten the hub nut from step 4 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 cotter pin does not line up always tighten to the next alignment XR099 7 Install the wheel and tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb alumi...

Page 163: ... brake lever for wear 2 Inspect the brake lever for elongation of the pivot hole 3 Inspect the reservoir for cracks and leakage 4 Inspect the banjo fitting for cracks and deterioration and the condition of the fittings threaded and com pression INSTALLING 1 Position the brake housing on the handlebar Secure with clamp screws then tighten securely XR090A 2 Using two new crush washers connect the ba...

Page 164: ...f 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 NOTE The O ring is used for shipping purposes and provides no function in operation 6 Cover the piston end of the housing with a shop towel then keeping fingers clear of piston travel apply compressed air to the fluid port ...

Page 165: ...n 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 into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing seals and brake piston PR715 PR7...

Page 166: ...sher 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 and tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb aluminium wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts 10 Remove the ATV from the support stand ...

Page 167: ... 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 168: ...nut securing each rear shock absorber to the frame and lower A arm Account for bushings and sleeves from each XR101A 4 Using Spring Tool compress the shock absorber spring remove the retainer and remove the spring CF341 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 spr...

Page 169: ...ring the tie rod end to the knuckle then remove the tie rod end from the knuckle XR148A 7 Remove the cap screws securing the ball joints to the knuckle XR011C 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 XR154A 11 Remove the snap ring from the ball joint then ...

Page 170: ...into the frame mounts and secure with the cap screws Only finger tighten at this time XR154A 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 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 screws ...

Page 171: ... secure the nut XR099 13 Install the wheel and tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb aluminium wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts 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...

Page 172: ...be replaced with a new lock nut 11 Remove the cap screws and lock nuts securing the A arms to the frame then remove the A arms 12 If being serviced remove the inserts and sleeve from the A arm XR104 CLEANING AND INSPECTING 1 Clean all A arm components using a pressure washer 2 Inspect the A arm for bends cracks and worn bush ings 3 Inspect the frame mounts for signs of damage wear or weldment dama...

Page 173: ...er pin and spread the pin to secure the nut NOTE If the cotter pin does not line up always tighten to the next alignment XR099 9 Secure the shock absorber to the frame and A arm with a cap screw and new lock nut Tighten to 50 ft lb XR101A 10 Install the wheel and tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb aluminium wheel w black nuts or 80 ft l...

Page 174: ...NSTALLING Install the wheel then using a crisscross pattern tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb aluminium wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts NOTE Make sure each wheel is installed on its proper hub as noted in removing the rotation arrow if applicable must indicate forward direction of rotation CHECKING INFLATING...

Page 175: ...tion 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 Replace shock...

Page 176: ...174 NOTES ...

Page 177: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 394 ...

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Arctic Cat 2015 XR, Service Manual

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Summary of Contents for 2015 XR

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