Arctic Cat 2016 Alterra 500 Service Manual Download | Manualshive

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31

Removing

Engine/Transmission

Many service procedures can be performed without
removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section for
this important information.

1. Remove the seat; then disconnect the battery (posi-

tive cable first).

2. Remove the left side engine cover and both side pan-

els; then drain the coolant into a suitable container.

XR151A

3. From the left side, remove the gear position switch

connector (A) and the speed sensor connector (B).

XR119B

4. Drain the engine oil into a suitable container.

5. Remove the front body panel; then remove both foot-

wells.

6. Remove the air inlet tube from air filter housing and

throttle body.

XR137B

7. Remove the air inlet and outlet ducts from the CVT

housing.

8. Loosen the clamps securing the air inlet duct and

remove the duct; then 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. TMAP Sensor Connector

G. ISC Connector

H. Fuel Injector Connector

XR158A

11. From the right side, disconnect the coil connector

(A) and O2 sensor (D); then disconnect the positive
cable (B) from the starter motor and the engine
ground cable (C) from the starter mounting flange.



AT THIS POINT

If the technician’s objective is to service Top-Side Com-
ponents, Left-Side Components, or Right-Side Compo-
nents, the engine/transmission does not have to be
removed from the frame.



AT THIS POINT

If the technician’s objective is to service/replace mag-
neto cover oil seals or the oil strainer (from beneath the
engine/transmission), the engine/transmission does not
have to be removed from the frame.

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Summary of Contents for 2016 Alterra 500

Page 1: ...www arcticcat com SERVICE MANUAL www arcticcat com ...

Page 2: ...29 Removing Engine Transmission 31 Servicing Engine 500 33 Servicing Engine 550 700 69 Installing Engine Transmission 109 Fuel Lubrication Cooling 111 Throttle Body 111 Throttle Cable Free Play 112 Gas Tank 112 Oil Pump 113 Liquid Cooling System 114 Troubleshooting 115 Electrical System 117 Battery 117 Electronic Power Steering EPS 118 Ignition Switch 120 Ignition Coil 121 Ignition Timing 121 Acce...

Page 3: ...ures to promote effi ciency and to improve clarity At the time of publication all information photographs and illustrations were technically correct Some photo graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Arctic Cat Inc constantly refines and improves its products no retroactive obligation is incurred All materials and speci...

Page 4: ...e 20 27 ENGINE TRANSMISSION Part Part Bolted To Torque ft lb N m Clutch Shoe 500 Crankshaft 147 199 Clutch Shoe 550 700 Crankshaft 221 300 Driven Pulley 500 Driveshaft 147 199 Driven Pulley 550 700 Driveshaft 162 220 Ground Wire Engine 8 11 Magneto Cover Crankcase 9 5 13 Speed Sensor Housing 550 700 Crankcase 8 5 11 5 Oil Drain Plug Engine 16 22 Clutch Cover Housing Crankcase 9 5 13 Cam Sprocket C...

Page 5: ...69 4 76 103 4 2 2 7 27 36 7 52 70 7 77 104 7 3 4 1 28 38 1 53 72 1 78 106 1 4 5 4 29 39 4 54 73 4 79 107 4 5 6 8 30 40 8 55 74 8 80 108 8 6 8 2 31 42 2 56 76 2 81 110 2 7 9 5 32 43 5 57 77 5 82 111 5 8 10 9 33 44 9 58 78 9 83 112 9 9 12 2 34 46 2 59 80 2 84 114 2 10 13 6 35 47 6 60 81 6 85 115 6 11 15 36 49 61 83 86 117 12 16 3 37 50 3 62 84 3 87 118 3 13 17 7 38 51 7 63 85 7 88 119 7 14 19 39 53 ...

Page 6: ...n in this manual 10 Store the ATV indoors in a level position Preparation After Storage Taking 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...

Page 7: ...ols are available from the Arctic Cat Service Department 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 the pre filt...

Page 8: ...otate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in CHECKING for the proper valve tappet clearance NOTE Rotating the valve adjuster dial counter clockwise will open the valve tappet clearance by 0 05 mm 0 002 in per mark E While holding the adjuster dial at the proper clear ance setting tighten the jam nut s...

Page 9: ...arbon ATV 0051 Adjust the gap to correct specification see General Infor mation Foreword for proper type and gap Use a feeler gauge to check the gap ATV0052 A new spark plug should be tightened 1 2 turn once the washer contacts the cylinder head A used spark plug should be tightened 1 8 1 4 turn once the washer con tacts the cylinder head Muffler Spark Arrester 1 Remove the three cap screws securi...

Page 10: ... new gasket and tighten to 16 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug 7 Start the engine while the ATV is outside on level ground and allow it to idle for a few minutes 8 Turn the engine off and wait approximately one min ute 9 Remove the oil level stick and wipe it with a clean cloth 10 Install the oil level stick and threa...

Page 11: ... been drained install 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 Shift Lever CHECKING ADJUSTMENT XR004A CAUTION Do not over fill the engine with oil Always make sure that the oil level is not above the upper mark CAUTION Any lubricant used in place of the rec...

Page 12: ...nder in a level position check the fluid level in the reservoir On the hand brake if 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 XR125 2 Compress the brake lever pedal several times to check for a firm brake If the brake i...

Page 13: ...nt 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 inspect the hydraulic brake hoses for cracks or other damage If found the bra...

Page 14: ...liary 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 Steering Body Controls XR087A 2 Remove the cap screws securing the CVT cover then using a rubber mallet gently tap ...

Page 15: ...aft 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 162 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 co...

Page 16: ... the 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 XR212 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 ...

Page 17: ...ews 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 shift lever knob 12 Install the seat making sure it locks securely in place Rear Body Panel Rack REMOVING NOTE If ...

Page 18: ...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 mounting ring is oriented correctly on the tab and seats fully through the pod WT601A Steering Post Tie Rods REMOVING 1 Remove the seat and side and side panels then remove the center a...

Page 19: ...the steering post arm and the left side and right side steering knuckles AF778D KX039 12 Remove two cap screws securing the lower steering post bearing flange to the frame then remove the steering post AL600D CLEANING AND INSPECTING 1 Clean and inspect the pivot area for wear Apply a low temperature grease to the ends 2 Inspect the tie rods for damaged threads or wear 3 Inspect the tie rods for cr...

Page 20: ...the cotter pins AF778D 4 Install the handlebar and secure with the handlebar caps Tighten the screws to 25 ft lb 5 Install the shock absorber and tighten to 50 ft lb 6 Install the handlebar cap then install the console and gauge INSTALLING Electronic Power Steering Models 1 Place the lower steering post into position then secure the lower bearing flange to the frame with two cap screws Tighten to ...

Page 21: ...ks 2 Inspect the grip for deterioration 3 If a grip is damaged cut the grip lengthwise using a sharp knife or box cutter then peel off the grip INSTALLING NOTE Before installing a grip use contact removal spray or alcohol to clean the handlebar of glue resi due oil or any other contaminant 1 Apply a liberal amount of Handlebar Grip Adhesive to the inside of a new grip 2 Slide the grip onto the han...

Page 22: ...ee Fuel Lubrica tion Cooling Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the wheel cap from the hub then remove the cotter pin from the nut 3 Remove the nut securing the hub 4 Remove the brake caliper NOTE Do not allow the brake caliper to hang from the cable hose 5 Remove the hub assembly 6 Remove the cotter ...

Page 23: ...s and secure with the two cap screws Tighten to 35 ft lb XR147A 3 Install the tie rod end and secure with the nut Tighten to 30 ft lb then install a new cotter pin and spread the pin XR148A 4 Apply a small amount of grease to the hub splines PR290A 5 Install the hub assembly onto the splines of the shaft 6 Secure the hub assembly with the nut Tighten only until snug XR099 7 Secure the brake calipe...

Page 24: ...not to push down or lift up on the front end then turn the handlebar to the straight ahead position NOTE When measuring and adjusting there should be a normal operating load on the ATV with out an operator but with Arctic Cat approved acces sories 4 Measure the distance from the outside edge of each handlebar grip to equal reference points on each side of the rear rack XR145A 5 Adjust the handleba...

Page 25: ...s NOTE Prior to locking 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 seat shift lever knob and left side panel 2 Remove the axle and nut securing the shift lever to the upper shift arm then remove the shift lever Account for a spring and two O rings INSTALLING 1 Place the spring into pos...

Page 26: ...afoil seal INSPECTING 1 Inspect muffler externally for cracks holes and dents 2 Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler NOTE For additional details on cleaning the muf fler spark arrester see Periodic Mainte nance Tune up INSTALLING 1 With the grafoil seal properly positioned install the muffler and secure wi...

Page 27: ...ws Tighten to 13 ft lb then connect the wir ing harness Checking Adjusting Headlight Aim The headlights can be adjusted vertically and horizon tally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the ATV on a level floor so the headlights are approximately 6 1 m 20 ft from an aiming sur face wall or similar aiming surface 0748 548 NOTE ...

Page 28: ...lace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Pro...

Page 29: ...gle 45 30 Valve Spring Free Length min 44 73 mm Valve Spring Tension 32 5 mm outer 17 23 kg 37 98 lb VALVES AND GUIDES 550 700 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 5 023 mm Valve Head Thickness min 2 3 mm Valve Seat Angle 45 15 30 Val...

Page 30: ...1 Gasoline bad contaminated 2 Spark plug fouled 3 Magneto defective 4 ECM defective 5 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 ar...

Page 31: ... 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 car...

Page 32: ... then 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 TMAP Sensor Connector G ISC Connector H Fuel Injector Con...

Page 33: ...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 34: ...r Head Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appro priate wrench rotate the crankshaft to top dead cen ter of the compression stroke NOTE Arctic Cat recommends the use of new gas kets lock nuts and seals and lubricating all internal components when servicing the engine transmission 1 Remove the cap screws ...

Page 35: ...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 36: ...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 37: ...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 38: ...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 39: ...e 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 install...

Page 40: ...l 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 orientation ATV 1085B 2 Install the compression rings 1 and 2 so the letter s on the top surface of each ring faces the dome of the piston R...

Page 41: ...ect any high spots before assembly by continu ing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained CC129D Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks or chips 2 If the chain guide is damaged it must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter ...

Page 42: ...ting Camshaft Bearing Journal 1 Inspect the bearing journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced NOTE If the journals are worn replace the cam shaft Inspecting Camshaft Spring Drive Pin 1 Inspect the spring and unloader pin for damage CF061A NOTE With the weight extended the unloader pin should be ...

Page 43: ... right side crankcase half NOTE The two cylinder to crankcase nuts will be tightened in step 9 FI622A C Cylinder Head Camshaft D Cylinder Head Cover Rocker Arms NOTE Steps 1 4 in the preceding sub section must precede this procedure 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder FI621 6 Place a new gasket into position on the cylinder Place the alignment...

Page 44: ... 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 lobes directed down toward the piston place the camshaft in position and verify that the tim ing mark on the magneto is visible through the inspection plug and that the timing m...

Page 45: ...haft then install the cap screw and tab washer Tighten cap screw only until snug CC404D FI612 18 Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed then install the cap screw threads coated with red Loctite 271 Tighten to 10 ft lb then bend the tab to secure the cap screw 19 Rotate the crankshaft until the first cap screw from step 17 securing t...

Page 46: ... tion then install and tighten the cap screws to 8 5 ft lb FI602 29 Install the spark plug and tighten securely then install the timing inspection plug Left Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transm...

Page 47: ... cap screws and the two longer cap screws FI596A 6 Remove the magneto cover and account for two alignment pins and the gasket D Rotor Flywheel E Starter Clutch Gear F Starter Motor NOTE Steps 1 6 in the preceding sub section must precede this procedure 7 Remove the nut securing the rotor flywheel on the crankshaft and install the crankshaft protector FI549 8 Using the Magneto Rotor Remover Set bre...

Page 48: ...uring the output drive gear to the output shaft and remove the gear noting that the hub flange is directed toward the crankcase FI564 FI566 Servicing Left Side Components INSPECTING STARTER CLUTCH GEAR 1 Place the starter clutch 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 shoul...

Page 49: ...e cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a crisscross pattern Make sure the one way bearing is installed with the notches directed away from the rotor flywheel FI576A FI578 REPLACING STARTER GEAR BEARING 1 Support the starter clutch gear in a press making sure to support the hub around the entire circumference then using a suitable bearing driv...

Page 50: ...en sor and one cap screw from the harness hold down 2 Lift the rubber grommet out of the housing then remove the stator coil crankshaft position sensor Account for and note the position of the harness hold down under the crankshaft position sensor FI590 3 Install the new stator coil assembly and secure with three cap screws Tighten to 15 ft lb 4 Place the stator wire harness hold down into posi ti...

Page 51: ...moved 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 lb 3 Install the shift detent cam making sure the washer is installed MD1086 4 Install the shift detent cam arm and spring 5 Install the gear shift shaft assembly and wash...

Page 52: ...y Tighten the cap screws to 8 ft lb FI541A FI539 12 Install the water pump cover with a new O ring and secure with the four cap screws Tighten to 8 ft lb FI538 13 Connect the coolant hoses to the water pump and secure with the hose clamps Tighten securely Right Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to ser...

Page 53: ... 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 holding the movable drive face onto the crankshaft MD1033 4 Remove the movable drive face and spacer Account for the movable drive face rollers and outer drive face cover MD1035 MD1034 MD1036 5 Using a 6 mm cap screw threaded into the ...

Page 54: ...talling pur poses 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 Centrifugal Clutch Assembly E Oil Pump Drive Gear F Oil Pump Driven Gear NOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the one way clutch noting the direction of the green dot or the word OUTS...

Page 55: ...riven gear Account for the drive pin and thrust washer MD1020 G Oil Pump Oil Strainer NOTE Steps 1 17 in the preceding sub sections must precede this procedure 18 Remove three cap screws holding the oil pump and remove the oil pump Account for two alignment pins MD1060 19 Remove the four cap screws securing the oil strainer cap then remove the Phillips head screws securing the oil strainer Account...

Page 56: ...e way clutch onto the clutch shoe assem bly with the green dot or the word OUTSIDE directed away from the clutch shoe KC330 2 Place the clutch housing onto the clutch shoe one way clutch NOTE It will be necessary to rotate the clutch housing counterclockwise to properly seat the one way clutch KC331A 3 Check that the clutch shoe can only be rotated coun terclockwise in respect to the clutch housin...

Page 57: ...secure with the four cap screws Tighten the cap screws to 10 ft lb then install the oil drain plug and tighten to 20 ft lb MD1208 3 Place two alignment pins and the oil pump into posi tion on the crankcase and secure with the Phil lips head screws coated with red Loctite 271 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 d...

Page 58: ...ive Face NOTE Steps 1 8 in the preceding sub section must precede this procedure 9 Install two alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 10 Tighten the clutch cover cap 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 Pl...

Page 59: ... with red Loctite 271 then making sure the splines of the clutch shaft pro trude through the cover plate secure with the nut and tighten to 147 ft lb KC138 KC141 NOTE At this point the cap screw can be removed from the driven pulley face 17 Rotate 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 ...

Page 60: ...e Separator Crankshaft Remover and tapping lightly with a rubber mallet separate the crankcase halves 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 a...

Page 61: ...ork 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 6 Remove the crank balancer driven gear G and account for a key then remove the crankshaft bal ancer shaft MD102...

Page 62: ...nge no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart Checking Tooth Contact NOTE...

Page 63: ... blocks and mount a dial indicator and base on the surface plate Position 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 deflection must not exceed specifications Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to...

Page 64: ...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 FI665 3 Remove the low driven gear washer then remove the low driven gear along with the bearing and bushing FI666 CAUTION Care should be taken to support the connecting rod when rotating the crankshaft CAUTION When ...

Page 65: ...ear 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 the snap ring FI671A FI670 2 Install the high low shift dog 6 on the countershaft and secure with snap ring 7 then install the s...

Page 66: ... 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 shaft was removed make sure that the proper shim is installed 1 Install the output shaft into the crankcase ma...

Page 67: ...can be installed using a crankshaft installer 4 Rotate the crankshaft so the counterweight is toward the rear of the engine Install the crank balancer shaft MD1024 5 Install the key in the crank balancer shaft then install the gear and aligning the timing marks slide the gear into place FI658 6 Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end ins...

Page 68: ...ank case FI653A FI655A 9 Install the input driveshaft FI646 10 Install the spacer 1 shaft 2 reverse idler gear and washer 3 FI641A FI645 11 Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses then install the center carrier bearing alignment C ring FI660A FI659A ...

Page 69: ...g 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 crankcase 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 CC871 5 In a crisscross pattern tighten the 8 mm cap screws until the halves a...

Page 70: ...ngine 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 inspec tion plug then using a socket and ratchet rotate the crankshaft to top dead center of the compression stroke 1 Remove the two tappet covers CC001D NOTE Keep the mounting hardware with the cov ers f...

Page 71: ...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 72: ...edure 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 CC024D AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub...

Page 73: ...ing 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 Valve Cover NOTE If the valve cover cannot be trued the cylin der head assembly must be replaced 1 Was...

Page 74: ...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 it must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replacement Arctic Cat recommends that the compo nents be taken to a qualified mac...

Page 75: ...ive 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 ring out of the ring groove CC400D 2 Remove each ring by working it toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will not be replaced with new ones note the location of each ring for proper installation When insta...

Page 76: ...il rings according to the illustration ATV 1085B NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation 2 The ring with the orientation mark MTOP or TOP should be installed in the second middle groove and the ring with the orientation mark M or O should be installed in the first top groove ATV 1024A ATV 1024B CYLINDER CYLINDER HEAD ASSEMBLY NOTE If the cyl...

Page 77: ... 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 finish is attained CC129D Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks or chips 2 If the chain gui...

Page 78: ... the camshaft on a set of V blocks then position the dial indicator contact point against the shaft and zero the indicator CC283D 2 Rotate the camshaft and note runout maximum runout 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...

Page 79: ... housing then remove the piston holder and seat the cylinder firmly on the crankcase CC024D 4 Loosely install the two nuts which secure the cylin der to the crankcase NOTE The two cylinder to crankcase nuts will be tightened in step 11 CC023D 5 Install the coolant hose onto the crankcase union and tighten the clamp C Cylinder Head D Valve Cover NOTE Steps 1 5 in the preceding sub section must prec...

Page 80: ...nder head Install the pivot cap screw and washer CD461 NOTE At this point oil the camshaft journals cam lobes and the three seating surfaces on the cylinder 14 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the cam shaft lobes onto the camshaft At this point do not seat the sprocket onto the shaft 732 307B 15 With the cam lobes directe...

Page 81: ...ew threads coated with red Loctite 271 securing the sprocket and tab washer to the camshaft Tighten only until snug CD464 19 Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed then install the cap screw threads coated with red Loctite 271 and tighten to 10 ft lb Bend the tab to secure the cap screw CD465 20 Rotate the crankshaft until the first ...

Page 82: ...s rotated clockwise The adjuster shaft tension will be released in step 25 24 Place the chain tensioner adjuster assembly and gas ket into position on the cylinder and secure with the two cap screws CD469 25 Using a flat blade screwdriver rotate the adjuster screw inside the tensioner counterclockwise until all tension is released then install the cap screw into the end of the chain tensioner CD47...

Page 83: ... is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Left Side Components A Outer Magneto Cover B Water Pump C Cover D Rotor Flywheel 1 Remove the four cap screws securin...

Page 84: ... water pump 7 Remove the cap screws securing the left side cover to the crankcase noting the location of the differ ent sized cap screws for installing purposes 8 Using an appropriate side case puller remove the side cover Account for a gasket and two alignment pins 9 Remove the nut securing the magneto rotor to the crankshaft then install the magneto rotor puller adapter NOTE The puller has left ...

Page 85: ... pin into the crankcase 14 Remove the shift shaft noting the timing marks for assembling purposes Account for two washers PR430A 15 Remove the gear shift cam plate and account for a washer then remove the cam stopper and cam stop per spring Account for two washers PR434A Servicing Left Side Components INSPECTING STARTER CLUTCH GEAR 1 Place the starter clutch gear onto the rotor flywheel and attemp...

Page 86: ...e cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a crisscross pattern Make sure the one way bearing is installed with the notches directed away from the rotor flywheel FI576A FI578 REPLACING STARTER GEAR BEARING 1 Support the starter clutch gear in a press making sure to support the hub around the entire circumference then using a suitable bearing driv...

Page 87: ... for and note the position of the harness hold down under the crankshaft position sensor FI590 3 Install the new stator coil assembly and secure with three new patch lock cap screws Tighten to 15 ft lb 4 Place the stator wire harness hold down into posi tion then install the crankshaft position sensor and secure with two cap screws Tighten securely 5 Install the upper cable hold down and secure wi...

Page 88: ...he gears are secured remove the oil passage plug from the crankcase 3 Install the two starter gear shafts then install the two starter gears with the beveled side of the intermedi ate gear facing inward as noted in removing CD139 H2 045 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 washe...

Page 89: ...fresh engine oil then place it into position on the two alignment pins Make sure the outer shift shaft washer is in place PR431A 9 Install the magneto cover and secure with the cap screws Tighten only until snug 10 Place the 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 ...

Page 90: ...er then tighten four cap screws to 6 ft lb Right Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A V Belt...

Page 91: ... two align ment pins CD973A NOTE For steps 7 12 refer to illustration H1 029A NOTE To aid in installing it is recommended that the assemblies are kept together and IN ORDER H1 029A 7 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 CF085 550 700 CAUTION Care must be taken when removi...

Page 92: ...screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer CC606 11 Using an impact wrench remove the cap screws securing the final drive carrier bearing housing D then remove the housing and account for two align ment pins CD999 12 Remove the snap ring securing the oil pump driven gear A then remove the gear noting the direction of the sides of the gear for installing ...

Page 93: ... 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 CC446D DRIVE CLUTCH ASSEMBLY Disassembling and Inspecting 1 Slide the sheave plate out of the movable drive sheave Make note of each drive face plate damper orientation before removing Check for excessive wear warping or any cracks Repla...

Page 94: ...the sheave plate into the movable drive sheave CF381 DRIVEN PULLEY ASSEMBLY Disassembling 1 Secure the clutch spring compressor base in a work vise attached to a stable work table or work bench WC422A 2 Place the driven pulley assembly onto the base and mark the fixed sheave movable sheave and cam then note the location of the spring anchors in the movable sheave and cam and mark them for assem bl...

Page 95: ...t the sheave faces for cracks grooving or checking WC381 WC383 2 Inspect the cam shoes on the movable driven sheave for chipping excessive scoring or general condition WC384A NOTE Always replace the cam shoes as a complete set 3 Inspect the cam ramp faces for galling scoring or excessive wear WC382 4 Inspect the key and keyways in the cam and fixed driven sheave for excessive wear 5 Inspect the we...

Page 96: ...stall the spring over the hub of the movable driven sheave engaging the spring into the previously marked spring anchor hole WC391A 4 Place the cam over the spring and align the spring tip to the previously marked anchor hole WC753 5 Install the centering bushing into the fixed driven hub then with the sharp side upward place the snap ring onto the assembly and install the compression yoke and win...

Page 97: ...A 8 Install the square key making sure it fits flush and clear of the snap ring groove then install the snap ring making sure it is seated properly WC412 WC419 9 Turn the wing nut counterclockwise slowly allowing the cam to contact the snap ring then loosen slightly and tap the cam with a plastic mallet to ensure the snap ring is securely seated WC408 10 Remove the wing nut compression yoke and ce...

Page 98: ...aft 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 washer Tighten the cap screw to 63 ft lb CD992 CD991 5 Grease the driven gear pin and insert the oil pump into the case Tighten the oil pump screws to 8 ft lb Install the washer and pin then install the driven gear noting...

Page 99: ...using a rubber mallet 10 Place the clutch cover housing assembly into posi tion on the crankcase then secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighten to 8 ft lb H1 023 11 Place the driven pulley assembly into position and secure with the bolt 550 or nut 700 Tighten to 80 ft lb 550 or 162 ft lb 700 CF262 12 Tighten the cap screw with was...

Page 100: ...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 right side cap screws securing the crankcase halves Note the location of the differ ent lengthed cap screws 2 Remove the left side cap screws securing the cran...

Page 101: ...DE677A 5 Remove the countershaft assembly D Account for a washer on each end of the countershaft CC674 NOTE Do not disassemble the countershaft assem bly unless necessary If necessary see Servicing Cen ter Crankcase Components sub section 6 Using a rubber mallet tap on the crankcase to remove the driveshaft CC675 7 Note the timing marks on the crank balancer assem bly B gear and crankshaft C gear ...

Page 102: ... using a plastic mallet drive the shaft out of the bearing Account for shim shims NOTE Shims should be measured and kept for a starting point in adjusting backlash Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set Up NOTE If the secondary output driven shaft is replaced or disassembled the initial set up must be performed to establish correct gear tooth contact If only...

Page 103: ...with machinist s lay out dye Rotate the shafts through several rota tions in both directions Gear contact should extend from the root to the top of the gear teeth MT016A 6 To adjust tooth contact use the following chart to correctly shim the driven shaft 7 After correct tooth contact is established proceed to Checking Backlash in this sub section Checking Backlash 1 If removed install the secondar...

Page 104: ...o the upper connecting rod small end bore then remove the gauge and measure it with micrometer CC290D 2 Maximum 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 Position the indicator contact point against the center of the connecting rod small end journal 2 Zer...

Page 105: ... assembling then remove the high driven gear outer washer high driven gear high driven gear bearing high driven gear bushing and high driven gear inner washer GZ283A 2 Remove the drive gear then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft GZ296 GZ312 3 Remove the reverse driven gear dog CAUTION Care should be taken to support the connecting rod when ro...

Page 106: ...Remove the reverse driven washer then remove the low driven gear locking washer GZ320 GZ319 GZ318A 6 Remove the low driven gear Account for a bearing bushing and thrust washer GZ316 Assembling 1 From the drive gear end install a thrust washer bushing and bearing then install the low driven gear and washer GZ317A GZ318 ...

Page 107: ...ear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap ring GZ288A GZ314 5 Install the reverse driven gear dog onto the counter shaft and secure with a snap ring GZ313A GZ312 6 From the opposite end of the countershaft install the high low driven gear dog A thrust washer B bushing C bearing D high low driven gear E and spacer washer F ...

Page 108: ...moke then slide the crankshaft assembly into place CC688 CC689 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft install ing tool 3 Install the crank balancer CD832B NOTE It will be necessary to rotate the crank bal ancer until the counterweight is facing away from the crankshaft then rotate the crankshaft clockwise into the journal area to allow the cr...

Page 109: ...y seated into the shift cams CC669 9 Install the reverse idler gear assembly noting the positioning of the two washers gear bushing and shaft CC668 10 Install the front and rear secondary driven shaft assemblies into the left side of the crankcase making sure the bearing locating pins are toward the top of the crankcase and the bearing C ring is fully seated in the crankcase PR787B 11 Place the oi...

Page 110: ...ng occurs 9 In a crisscross case to case pattern tighten the 6 mm cap screws from steps 6 7 to 8 ft lb NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs Installing Engine Transmission 1 From the left side place the engine into the frame 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 nut...

Page 111: ...onnect 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 Con...

Page 112: ...uel rail 4 Remove the screws securing the throttle 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 TMAP sensor fuel injector connector ISC connector and TPS connector 8 Loosen the clamp securing the air filte...

Page 113: ... Release the throttle lever 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 mm 1 8 1 4 in at t...

Page 114: ...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 existing cap screws Tighten to 8 ft lb 5 Install the battery tray and secure with the mounting clips and torx head screw Tighten the screw securely 6 Install t...

Page 115: ...e the front body panel rack 3 Remove the upper and lower coolant hoses 4 Remove the cap screws and nuts securing the radia tor to the frame 5 Disconnect the fan wiring from the main wiring har ness then remove the radiator fan assembly and account for the grommets and collars 6 Remove the fan fan shroud assembly from the radia tor Cleaning and Inspecting 1 Flush the radiator with water to remove a...

Page 116: ...r see RADIATOR in this sub section 2 Remove the fan assembly from the radiator Installing 1 Position the fan assembly on the radiator then secure with existing hardware NOTE The fan wiring must be in the upper right position 2 Install the radiator WATER PUMP NOTE On the 550 700 the water pump is a non serviceable component It must be replaced as an assembly On the 500 to service the water pump see...

Page 117: ...lem Idling or low speed impaired Condition Remedy 1 Gas contaminated 2 TPS out of adjustment 3 Air filter housing contaminated 4 ISC malfunction 1 Drain gas tank and fill with clean gas 2 Adjust TPS 3 Clean or replace air filter housing or replace 4 Inspect replace ISC Problem Medium or high speed impaired Condition Remedy 1 Gas contaminated 2 Air filter housing contaminated 1 Drain gas tank and f...

Page 118: ...provided with bat tery chargers and battery products NOTE Refer to all warnings and cautions provided with the battery or battery maintainer charger Loss of battery charge may be caused by ambient tem perature 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 a...

Page 119: ...y becomes hot to the touch stop charging Resume after it has cooled 7 Once the battery has reached full charge unplug the charger from the 110 volt electrical outlet 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 Electronic Power Steering EPS NOTE Certain models have been produced with ...

Page 120: ...roken ACG stator wires EPS will auto recover when engine RPM signal returns to normal C1315 Engine RPM Faulty Engine RPM CAN signal received by the EPS incorrect or missing Broken main harness CAN wires or defective ECM EPS will auto recover when engine RPM signal returns to normal C1316 EEPROM Error EPS internal memory error has been detected Internal EPS condition Correct EPS condition C1317 CAN...

Page 121: ...nition Switch The ignition switch harness connects to the switch with a four pin connector To access the connector remove the gauge then remove the ignition switch nut remove the switch and press the connector release tab Pull the con nector from the switch XR105A XR107A VOLTAGE NOTE Perform this test on the harness connector 1 Set the meter selector to the DC Voltage position 2 Connect the red me...

Page 122: ...ster lead to the other terminal 2 The meter reading must be within specification NOTE Secondary coil resistance checks are not rec ommended An internal diode in the coil prevents accurate secondary resistance measurements Spark Plug Cap 1 Connect the red tester lead to one end of the cap then connect the black tester lead to the other end of the cap AR603D 2 The meter reading must be within specif...

Page 123: ...LO Beam 1 Connect the red tester lead to the white wire then connect the black tester lead to the brown black wire 2 With the dimmer switch in the LO position the meter must show an open circuit NOTE If the meter reads resistance replace the switch DIODE Starter Button NOTE If voltage is not as specified check the con dition of the battery in the meter prior to replacing the switch A low battery w...

Page 124: ...wire terminal then connect the black tester lead to the black wire terminal 5 With the switch in the 2WD position the meter must show an open circuit With the switch in the 4WD position the meter must show an open circuit With the switch in the 4WD Lock position the meter must show less than 1 ohm NOTE If the meter does not show as specified replace the drive select switch RESISTANCE Gear Position...

Page 125: ...e red tester lead to the white red wire and the black tester lead to the black wire The meter must show battery voltage NOTE If battery voltage is not shown in any test inspect the LIGHTS fuse battery main wiring har ness connectors or the left handlebar switch VOLTAGE Taillight NOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the LIGHTS positi...

Page 126: ...range wire and black meter lead to ground With the ignition switch in the on position the meter must read battery voltage Resistance With the connector still removed from the injector place the red meter lead to either terminal then connect the black tester lead to the other terminal Reading is typi cally 12 ohms NOTE If voltage is not present troubleshoot the battery connector pins wiring harness...

Page 127: ...e meter does not read as specified replace the sensor ENGINE COOLANT TEMPERATURE ECT SENSOR NOTE Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge see EFI Diagnostic System in this section 1 Connect the meter leads selector in OHMS position to the sensor terminals 2 Suspend the sensor and a thermometer in a container of cooking oil then heat the oil N...

Page 128: ...t ser viceable components If either component fails it must be replaced Testing 1 Blow any debris from the fuel pump connection using compressed air 2 Disconnect the quick connect fitting by pushing it toward the fuel pump fitting the press the quick con nect button s and remove the gasline hose XR171 3 Install Fuel Pressure Tester in line between the fuel pump and the gasline hose 4 Turn the igni...

Page 129: ...position and 95 ohms at empty fuel position NOTE If readings are erratic clean the resistor wiper and resistor with clean alcohol and retest If still not correct replace the fuel level sensor Installing 1 Mark the new fuel pump with a reference mark in the same location as the removed pump then place the new gasket on the pump 2 Remove the material covering the fuel pump open ing then carefully gu...

Page 130: ...eadings are not as specified the tilt sensor is defective XR199 NOTE When replacing the sensor after testing make sure the arrow marking is directed up CD705D THROTTLE POSITION 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 Verifying TPS Adjustment Tool Before using the TPS adjustment tool v...

Page 131: ...gauge should read 0 66 0 70 500 or 0 58 0 62 550 700 and at Wide Open Throttle it should read up to approxi mately 3 88 500 or 3 7 550 700 FI673A NOTE If the throttle body ECM TPS or ISC are replaced the EFI system must be synchronized Use the following procedure 1 With the key off depress throttle lever to Wide Open Throttle WOT 2 Place the ignition key in the ON position and wait for 10 seconds ...

Page 132: ...e gas tank TESTING 1 Start engine and warm up to normal operating tem perature then connect a multimeter to the battery as follows 2 Select the DC Voltage position then connect the red tester lead to the positive battery post and the black tester lead to the negative battery post 3 Start the engine and slowly increase RPM The volt age should increase with the engine RPM to a maxi mum of 15 5 DC vo...

Page 133: ... then remove the starter motor Account for the wiring forms and an O ring INSTALLING 1 Apply a small amount of grease to the O ring seal on the starter motor then 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 Starter Relay 1 Remove the seat and lef...

Page 134: ...hrottle lever and wait an additional 10 seconds 4 Turn the key to the OFF position and allow the gauge to shut off EFI Diagnostic System DIGITAL GAUGE The digital gauge can be used as a diagnostic tool for many of the DTC s displayed To place the gauge into the diagnostic mode use the following procedure 1 Turn the ignition switch ON 2 Depress and hold both left and right buttons together for appr...

Page 135: ...mperature in Fahrenheit or Celsius DTC P0112 P0113 P0114 Usage Verify correct output of IAT sensor NOTE After engine has been running IAT read ings 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 barometric pressure signal correct NOTE Local b...

Page 136: ...refix denotes a power train malfunction and a U prefix denotes a CAN communication related code NOTE Normal malfunction codes are cleared from the LCD when the component is replaced or the mal function is corrected however intermittent codes must be cleared as noted in the code chart Code Fault Description Possible Cause Fault Recovery Method C0063 Tilt Sensor Circuit High Sensor or interconnect h...

Page 137: ...ctor Balance Open Injector has been disconnected or interconnect harness open Correct condition P0336 Crankshaft Angle Sensor Synchronization Sensor or interconnect harness intermittent Correct condition P0337 Crankshaft Angle Sensor Circuit SG Sensor or interconnect harness shorted to chassis ground Correct condition P0339 Crankshaft Angle Sensor Intermittent Erratic Sensor or interconnect harnes...

Page 138: ...efective or shorted to battery power Correct condition P2300 Rear Ignition Coil Primary Circuit Low SG Open Coil or interconnect harness open or shorted to chassis ground Correct condition P2301 Rear Ignition Coil Primary 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 short...

Page 139: ...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 140: ...r makes squealing or grinding sounds the actuator must be replaced 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 the...

Page 141: ...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 securing the hex nuts then remove the hex nuts XR099 6 Release the brake lever lock NOTE It is...

Page 142: ...lease 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 differential mounting cap screw Account for a lock nut and washers CD026 17 Remove the upper differentia...

Page 143: ...may vary from model to model The technician should use discretion 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 remov...

Page 144: ...nion 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 GC014 ...

Page 145: ...ace 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 Using a T 40 torx wrench remove the cap screws securing the pinion housing Account for the coupler fork and spring differential ...

Page 146: ...der 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 in 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...

Page 147: ... running tolerances Gear life and gear noise are greatly affected by these tolerances therefore it is very import ant to properly adjust any gear set prior to final assembly 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 proceed ing Backlash NOTE Always set backlas...

Page 148: ...n 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 1 6 mm 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 t...

Page 149: ...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 assembled see Assembling Differential Assembly in this sub section Assembling Differential Assembly 1 With the pinion ...

Page 150: ...ten the cap screws evenly to 23 ft lb existing housing or 28 ft lb new housing NOTE Grease can be applied to the O ring for ease of assembling 6 Install the shift fork shaft w spring into the housing making sure the shaft O ring is positioned to the inside CC892 7 Install the shift fork assembly making sure the fork leg is facing upward Apply a small amount of oil to the gasket then install the ga...

Page 151: ...our holes in the output flange and install the four cap screws coated with blue Loctite 243 Tighten to 20 ft lb Pull the rubber boot over the out put flange and input shaft Be sure to align the oil rings over the recess XR169 3 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid gear lubricant into the differential and install the fill plug Tighten to 16 ft lb 4 Install the front drive actuator with the th...

Page 152: ... not allow the brake calipers to hang from their cable hose 6 Slide the hub out of the knuckle and set aside 7 Remove the cap screw and lock nut securing the knuckle to the upper A arm Discard the lock nut NOTE Never reuse a lock nut Once a lock nut has been removed it must be replaced with a new lock nut 8 While holding the drive axle stationary pull the top of the knuckle out and down until it i...

Page 153: ...ot Clamp Tool remove and retain both clamps for assembly purposes CF636 2 Place the white striped end of the CV joint into a vise CF638 3 To disengage the axle from the CV joint sharply pull back on the axle then slide the boot off of the axle CF637 NOTE Steps 1 3 can be used to replace the out board boot ASSEMBLING AXLES 1 Install the inner boot with the small clamp making sure the ends of the cl...

Page 154: ...V from the support stand and release the brake lever lock INSTALLING FRONT DRIVE AXLE 1 Position the drive axle in the gear case and steering knuckle then insert the upper A arm ball joint into the steering knuckle Secure with a cap screw tight ened to 50 ft lb 2 Place the brake hose into position on the upper A arm then secure the lower shock eyelet to the A arm with a cap screw and a new lock nu...

Page 155: ...E Ring gear clearance must be adjusted prior to selecting shim for the thrust button 1 Install the thrust button with shim into the gear case cover and tighten securely left hand threads GC057A 2 Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge Clearance should be 0 020 0 040 in GC058A 3 If clearance is as specified r...

Page 156: ...ply grease to the splines in the hub 3 Install the hub assembly onto the shaft PR290 4 Secure the hub assembly with the hex nut Tighten only until snug 5 Secure the brake caliper to the knuckle with two new patch lock cap screws Tighten to 20 ft lb XR012A 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 ea...

Page 157: ... housing then remove the brake lever and set aside 4 Remove the clamp screws securing the brake hous ing to the handlebar then remove the assembly from the handlebar XR090A INSPECTING 1 Inspect the pin securing the 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 a...

Page 158: ...rake 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 to ...

Page 159: ...inding 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 PR717A 2 Press the piston into the caliper housing using hand pressure only Completely seat the piston then wipe off any excessive brake fluid PR71...

Page 160: ...eriodic Maintenance Tune up 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 aluminum wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts 10 Remove the ATV from the support stand and verify brake operation CAUTION If brake pads become contaminated with brake fluid they must be thoroughly cleaned with brake cleaning sol...

Page 161: ... 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 162: ...er A arm Discard the nuts XR100A 3 Remove the two cap screws and 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...

Page 163: ...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 164: ... 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 to 5...

Page 165: ...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 aluminum 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 the wheel 4 Remove and di...

Page 166: ... 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 damage INSTALLING 1 Install the A arm assemblies into the frame and secure with the cap screws and new lock nuts Only finger tighten at this time 2 Slide the knuckle onto the drive axle and into posi tion on the A arms then se...

Page 167: ...1 Remove the ATV from the support stand Rear Sway Bar REMOVING 1 Remove and discard the cap screws and lock nuts securing the sway bar link to the lower A arms on both sides XR096C 2 Remove the cap screws securing the sway bar to the frame and remove the sway bar Account for the bushing retainers and bushings XR101B INSPECTING 1 Inspect the sway bar for any signs of twisting or cracking 2 Inspect ...

Page 168: ... 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 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 specifi...

Page 169: ...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 170: ...169 NOTES ...

Page 171: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 682 2015 Arctic Cat Inc Effective September 2015 ...

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