Arctic Cat 2016 Alterra 500, Service Manual

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Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition Remedy
1. Drive - driven bevel gears damaged - worn
2. Backlash incorrect
3. Tooth contact improper
4. Bearing damaged
5. Gears worn
6. Splines worn
1. Replace gears
2. Adjust backlash
3. Adjust contact
4. Replace bearing
5. Replace gears
6. Replace shaft(s)
Problem: Engine idles poorly
Condition Remedy
1. Gasoline bad - contaminated
2. Valve clearance incorrect
3. Valve seating poor
4. Valve guides defective
5. Rocker arms - arm shaft worn
6. Magneto defective
7. ECM defective
8. Spark plug fouled - gap incorrect
9. Ignition coil defective
10. Fuel injector obstructed
1. Drain gas - replace with clean gas
2. Adjust clearance
3. Replace - service seats - valves
4. Replace guides
5. Replace arms - shafts
6. Replace stator coil
7. Replace ECM
8. Adjust gap - replace plug
9. Replace ignition coil
10. Replace fuel injector
Problem: Engine runs poorly at high speed
Condition Remedy
1. Gasoline bad - contaminated
2. High RPM “cut out” against RPM limiter
3. Valve springs weak
4. Valve timing incorrect
5. Cams - rocker arms - tappets worn
6. Spark plug gap incorrect
7. Ignition coil defective
8. Fuel pump defective
9. Air cleaner element obstructed
10. Fuel hose obstructed
1. Drain gas - replace with clean gas
2. Shift into higher gear - decrease speed
3. Replace springs
4. Time valves
5. Replace cams - arms - tappets
6. Adjust gap
7. Replace ignition oil
8. Replace fuel pump
9. Clean element
10. Clean or replace hose
Problem: Exhaust smoke dirty or heavy
Condition 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
Condition Remedy
1. Gasoline bad - contaminated
2. Valve and/or combustion chamber carbon build-up
3. Valve clearance incorrect
4. Valve springs weak
5. Valve timing incorrect
6. Piston ring(s) - cylinder worn
7. Valve seating poor
8. Spark plug fouled
9. Rocker arms - shafts worn
10. Spark plug gap incorrect
11. Fuel injector obstructed
12. Cam chain worn
13. Air cleaner element obstructed
14. Engine oil overfilled - contaminated
15. Intake manifold leaking air
1. Drain gas - replace with clean gas
2. Run combustion chamber cleaner or clean combustion chamber
3. Adjust clearance
4. Replace springs
5. Re-time valve gear
6. Replace - service rings - cylinder
7. Repair seats
8. Clean - replace plug
9. Replace arms - shafts
10. Adjust gap - replace plug
11. Replace injector
12. Replace cam chain
13. Clean element
14. Drain excess oil - change oil
15. Tighten - replace manifold
Problem: Engine overheats
Condition Remedy
1. Radiator obstructed
2. Radiator hoses - cap damaged - obstructed
3. Fan malfunctioning
4. Fan relay malfunctioning
5. Thermostat stuck - closed
6. Coolant level low
7. Octane low - gasoline poor
8. Intake manifold leaking air
9. Carbon deposit (piston crown) excessive
10. Oil low
11. Oil pump defective
12. Oil circuit obstructed
1. Clean radiator
2. Clear obstruction - replace hoses
3. Replace fan relay
4. Check fan fuse - replace fan
5. Replace thermostat
6. Fill - examine system for leaks
7. Drain - replace gasoline
8. Tighten - replace manifold
9. Clean piston
10. Add oil
11. Replace pump
12. Clean circuit