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Arctic Cat 350 2011, Service Manual

The Arctic Cat 350 2011 Service Manual is essential for anyone who owns this ATV model. This comprehensive manual is available for free download on our website, providing users with detailed instructions and valuable information required for servicing and maintaining their vehicle. Visit manualshive.com to access this helpful manual effortlessly.

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3-64

8. Using the Magneto Rotor Remover Set, break the

rotor/flywheel loose from the crankshaft; then

remove the puller and crankshaft protector and

remove the rotor/flywheel.

FI550

9. Remove the flywheel key from the crankshaft;

then remove the starter clutch gear.

FI551A

10. Remove starter idler gears and their respective

shafts; then remove 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 snap ring securing the output drive

gear to the output shaft and remove the gear noting

that the hub flange is directed toward the crank-

case.

FI564

FI566

Section

Table of Contents

Manual

Table of Contents

For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

Summary of Contents for 350 2011

Page 1: ...he symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death A CAUTION identifies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE identifies supplementary information...

Page 2: ... Information Specifications 2 Periodic Maintenance 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 1 2 3 4 5 6 7 8 9 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 3: ...2 Torque Specifications 1 2 Torque Conversions ft lb N m 1 3 Break In Procedure 1 4 Gasoline Oil Lubricant 1 4 Genuine Parts 1 5 Preparation For Storage 1 5 Preparation After Storage 1 5 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 4: ...e Crankshaft 147 199 Clutch Cover Housing Assembly Crankcase 8 11 Left Side Cover Crankcase 8 11 Crankcase Half 6 mm Crankcase Half 10 13 5 Crankcase Half 8 mm Crankcase Half 21 28 Cylinder Nut Crankcase Half 8 11 Cylinder Head Cap Screw Crankcase 28 38 Cylinder Head Nut Cylinder 20 27 Cylinder Head 6 mm 350 Cylinder 8 11 Cylinder Head 8 mm 350 Cylinder 20 27 Cylinder Head Cover 350 Cylinder Head ...

Page 5: ...ose Master Cylinder 20 27 Brake Hose Auxiliary Brake Cylinder 20 27 Master Cylinder Rear Frame 8 11 Master Cylinder Clamp Front Master Cylinder 5 5 8 Hydraulic Caliper Knuckle 20 27 Auxiliary Brake Pedal Pivot 20 27 ft lb N m ft lb N m ft lb N m ft lb N m 1 1 4 26 35 4 51 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 ...

Page 6: ...gasoline it is not neces sary to add a gasoline antifreeze since ethanol will pre vent the accumulation of moisture in the fuel system RECOMMENDED ENGINE TRANSMISSION OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil which has been specifi cally formulated for use in this Arctic Cat engine Although Arctic Cat ACX All Weather synthetic engine oil is the only oil reco...

Page 7: ... tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 8 On the 425 fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant 9 On the 350 turn the gas tank valve to the OFF position 10 Disconnect the battery cables then remove the battery clean the battery posts and cables and ...

Page 8: ...ews and bolts are tightened to specifications 8 Check tire pressure Inflate to recommended pres sure as necessary 9 Make sure the steering moves freely and does not bind 10 Check the spark plug Clean or replace as neces sary CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system CAUTION Connect the positive battery cable f...

Page 9: ...r 2 6 Adjusting Throttle Cable 2 7 Adjusting Engine RPM Idle 2 7 Engine Transmission Oil Filter 2 8 Front Differential Rear Drive Lubricant 2 9 Tires 2 9 Driveshaft Coupling 2 10 Nuts Bolts Cap Screws 2 10 Ignition Timing 2 10 Lights 2 10 Shift Lever 2 12 Frame Welds Racks 2 13 Hydraulic Brake Systems 2 13 Burnishing Brake Pads 2 14 Checking Replacing V Belt 2 15 Manual Table of Contents For Disco...

Page 10: ... or 100 Miles Every 3 Months or 300 Miles Every 6 Months or 500 Miles Every Year or 1500 Miles As Needed Battery I I C Fuses I R Air Filter Drain Tube I I C R Valve Tappet Clearance I I A Engine Compression I Spark Plug I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R Carburetor Float Chamber 350 D Engine Idle RPM 350 I I A Engine Transmission...

Page 11: ...Air Filter Cleaner and Foam Air Fil ter Oil are available from Arctic Cat 4 Dry the element 5 Put the element in a plastic bag then pour in air filter oil and work the oil into the element Insert the forming spring into the element with the closely wrapped end of the spring toward the open end of the element 6 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the carburet...

Page 12: ...he TDC position on the compression stroke NOTE At this point the rocker arms and adjuster screws must not have pressure on them Feeler Gauge Procedure Using a feeler gauge check each valve tappet clear ance If clearance is not within specifications loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications Tighten each jam nut securely after completing the...

Page 13: ...the spark plug 2 Using compressed air blow any debris from around the spark plug 3 Remove the spark plug then attach the high ten sion lead to the plug and ground the plug on the cylinder head well away from the spark plug hole 4 Attach the Compression Tester Kit NOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the throttle lever in the full open pos...

Page 14: ...nce with the coolant manufacturer s recommendations While the cooling system is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engine off and then fill the cooling system to the bottom of the stand pipe in the radiator neck Checking Filling 1 Locate the coolant reservoir on the right side behind the radiator KC338B 2 Remove the cap an...

Page 15: ... until the throttle cable has proper free play of 3 6 mm 1 8 1 4 in at the lever ATV 0047 3 Tighten the jam nut against the throttle cable adjuster securely then slide the rubber boot over the adjuster Adjusting Engine RPM Idle NOTE Engine idle RPM is not adjustable on the 425 To properly adjust the idle RPM a tachometer is nec essary To adjust idle RPM use the following proce dure 1 With the tran...

Page 16: ...oil level stick filler plug 9 Start the engine while the ATV is outside on level ground and allow it to idle for a few minutes 10 Turn the engine off and wait approximately one minute 11 Remove the oil level stick and wipe it with a clean cloth 12 Install the oil level into engine case NOTE The oil level stick should be threaded into the case for checking purposes 13 Remove the oil level stick the...

Page 17: ...ined install the drain plugs and tighten to 45 in lb 5 Pour the appropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole 6 Install the fill plugs and tighten to 16 ft lb NOTE If the differential rear drive oil is contami nated with water inspect the drain plug filler plug and or bladder Tires TIRE SIZES The ATV is equipped with low pressure tubeless tires of the size an...

Page 18: ...f ignition timing cannot be verified the rotor may be damaged the key may be sheared the trigger coil bracket may be bent or damaged or the CDI unit ECU may be faulty Lights Rotate the ignition switch to the lights position the headlights and taillights should illuminate Test the brakelights by compressing the brake lever The brake lights should illuminate HEADLIGHTS NOTE The bulb portion of a hea...

Page 19: ...b counterclockwise to remove Press in and turn clockwise to install the bulb 3 Insert the bulb socket assembly into the housing and turn it clockwise to secure RUNNING LIGHTS BACK UP LIGHTS The running lights are located outboard of the head lights and the back up lights are outboard of the tail lights brakelights To replace the bulbs use the following procedure 1 Rotate the bulb socket counterclo...

Page 20: ...se to lower the beam KC406A Shift Lever CHECKING ADJUSTMENT KC165 With the engine stopped and the brake lever lock engaged turn the ignition switch to the ON position then shift the transmission into each of the gear posi tions and note that the gear position indicated on the LCD corresponds to the gear position selected by the lever If the indicator does not correspond to the selected gear it wil...

Page 21: ...dal several times to check for a firm brake If the brake is not firm the system must be bled 3 To bleed the brake system use the following pro cedure A Remove the cover and fill the reservoir with DOT 4 Brake Fluid B Install and secure the cover then slowly com press the brake lever pedal several times C Remove the protective cap install one end of a clear hose onto one FRONT bleeder screw and dir...

Page 22: ...to the knuckle and or axle housing with the cap screws Tighten to 20 ft lb PR377B 5 Install the wheel Tighten to 40 ft lb 6 Burnish the brake pads see Burnishing Brake Pads in this section Burnishing Brake Pads Brake pads both main and auxiliary must be bur nished to achieve full braking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the...

Page 23: ... two alignment pins and a gas ket KC142A 3 Remove the nut securing the movable drive face to the clutch shaft then remove the movable drive face assembly being careful not to let the roller fall out Account for a bushing KC127 KC128 4 Thread a cap screw from the V belt cover into the driven pulley fixed face and push the movable face open allowing the V belt to drop down between the pulley faces a...

Page 24: ...nt of the driven pulley and place it over the clutch shaft KC135 KC131 2 Install the bushing over the clutch shaft then install the movable drive face assembly on the clutch shaft KC128 KC138 3 With two drops of red Loctite 271 on the threads and with the splines of the clutch shaft protruding through the movable drive face install the nut and tighten to 147 ft lb KC152A KC141 Section Table of Con...

Page 25: ...asket in place install the V belt cover Using the pattern shown secure with the cap screws tightened to 8 ft lb KC142A KC153A 6 Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder then secure with the flat washer and cap screw and tighten to 20 ft lb KC149A Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 5...

Page 26: ...LE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 Table of Contents 350 3 6 Table of Contents 425 3 46 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 27: ...0 mm Valve Stem Runout max 0 10 mm Valve Head Thickness min 2 30 mm Valve Face Seat Width min intake exhaust 1 687 mm 2 687 mm Valve Seat Angle intake exhaust 45 Valve Face Radial Runout max 0 20 mm Valve Spring Free Length min 40 4 mm Valve Spring Tension 31 1 mm outer 21 4 kg 47 18 lb VALVES AND GUIDES 425 Valve Face Diameter intake exhaust 35 0 mm 30 5 mm Valve Tappet Clearance cold engine inta...

Page 28: ... 1 Clean vent hose 2 Replace valve 3 Clean replace hose 4 Clean replace inlet screen valve screen 5 Replace fuel pump Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Carburetor jets obstructed 350 5 Valve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Exc...

Page 29: ...ocker arms arm shaft worn 5 Magneto defective 6 CDI unit defective 7 Spark plug fouled gap too wide 8 Ignition coil defective 9 Float out of adjustment 350 10 Jets obstructed 350 11 Pilot screw setting improper 350 12 Idle Step Control ISC malfunction 425 1 Adjust clearance 2 Replace service seats valves 3 Replace cylinder head 4 Replace arms shafts 5 Replace magneto 6 Replace CDI unit 7 Adjust ga...

Page 30: ...lace springs 3 Re time valve gear 4 Replace service rings cylinder 5 Replace cylinder head valves 6 Clean replace plug 7 Replace arms shafts 8 Adjust gap replace plug 9 Clean jets 10 Adjust float height 11 Clean element 12 Drain excess oil change oil 13 Tighten replace manifold 14 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 2 Oil low 3 Octane...

Page 31: ...ft and right footwells and front body panel see Steering Frame then disconnect the negative battery cable from the bat tery 2 Remove the heat shield then remove the gas tank see Fuel Lubrication Cooling 3 Remove the oil fittings from the engine and account for two O rings then disconnect the oil temperature connector and cooling fan connector KC251 KC250 KC249 4 Disconnect the speedometer sensor t...

Page 32: ...the cylinder head then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe Account for a grafoil seal and seal ring KC170 KC238 7 Disconnect the gear position switch starter cable and engine ground cable then disconnect the trig ger coil and stator coil connectors KC228C Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606...

Page 33: ...emoved from the frame for this procedure Removing Top Side Components A Valve 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 compon...

Page 34: ... CF007A MD1354A 3 Loosen the cap screw on the end of the cam chain tensioner then remove the two cap screws secur ing the cam chain tensioner assembly Remove the tensioner assembly and gasket MD1245 4 Remove the cam chain tensioner pivot cap screw and washer MD1251 5 Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft MD1136 MD1137 Section Table of Contents Man...

Page 35: ...emove the two lower nuts securing the cylinder head to the cylinder one in front and one in rear MD1192 9 Remove the four cylinder head cap screws and washers Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left spark plug side CD211 10 Remove the cylinder head from the cylinder remove the gasket and account for...

Page 36: ...9 NOTE Support the connecting rod with rubber bands to avoid damaging the rod or install a con necting rod holder NOTE If the existing rings will not be replaced with new rings note the location of each ring for proper installation When replacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence AT THIS POINT To service cylinder see Serv...

Page 37: ... spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Keep all valves and valve components as a set Note the original location of each valve set for use during installation Return each valve set to its original location during installation 1 Using a valve spring compressor compress the va...

Page 38: ...lve face ATV 1004 2 Acceptable width must be at or above specifica tions Measuring Valve Face Radial Runout 1 Mount a dial indicator on the surface plate then place the valve stem on a set of V blocks 2 Position the dial indicator contact point on the out side edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications ...

Page 39: ...de Diameter 1 Using a micrometer measure the outside diameter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifications Installing Valves 1 Apply grease to the inside surface of the valve seals then place a lower spring seat and valve guide seal over each valve guide CC144D 2 Insert each valve into its original valve location 3 Install the valve springs with the pai...

Page 40: ...gle and to a sharp edge 2 Using the sharpened ring as a tool clean carbon from the ring grooves Be sure to position the ring with its tapered side up Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cylinder 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must be...

Page 41: ... ASSEMBLY NOTE If the cylinder cylinder head assembly cannot be trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chamber being careful not to nick scrape or damage the combustion chamber or the sealing surface 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a hel...

Page 42: ... 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 in three locations from top to bottom and again from top to bottom at 90 from the first measurements for a total of six measurements The trueness out of roundness is the difference between the highest and lowest reading Maximum trueness out of roundness must no...

Page 43: ... If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Loosen the jam nuts and adjuster screws CC005D 2 Place a strip of plasti gauge in each of the cam shaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap screws Tighten securely NOTE Do not rota...

Page 44: ...stalling Top Side Components A Piston B Cylinder 1 Lubricate the piston pin connecting rod and pis ton pin bore with motor oil then install the piston on the connecting rod making sure there is a cir clip on each side and the open end of the circlip is directed upwards or downwards NOTE The piston should be installed so the arrow points towards the exhaust MD1213 2 Place the two alignment pins int...

Page 45: ...s procedure 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder MD1349 6 Place a new gasket into position on the cylinder Place the alignment pins into position then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity MD1347 CAUTION The cylinder should slide on easily Do not force the cylinder or ...

Page 46: ...ar cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer CD383 12 With the alignment pin installed in the camshaft and the cam lobes directed down toward the pis ton place the camshaft in position and verify that the timing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cove...

Page 47: ...cam shaft then install the cap screw and tab washer Tighten cap screw only until snug CC404D MD1137 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 11 ft lb then bend the tab to secure the cap screw MD1137 19 Rotate the crankshaft until the first cap screw from step ...

Page 48: ...f the valve cover then place the valve cover into position Note that the two align ment pins are properly positioned NOTE At this point the rocker arms and adjuster screws must not have pressure on them 27 Install the four top side cap screws with rubber washers then install the remaining cap screws Tighten only until snug MD1261 28 In a crisscross pattern starting from the center and working outw...

Page 49: ...ap screws in order for installing purposes MD1186 3 Using Crankcase Separator Crankcase Remover and the 6 mm adapter remove the left side cover w stator assembly Account for the two alignment pins and the position of the shifter bracket for installing purposes CC946 MD1188 NOTE Inspect the inside of the left side cover for any shaft washers that may have come off with the cover Make sure they are ...

Page 50: ...idler gear No 1 and starter idler gear No 2 MD1305 8 Remove the gear shift shaft assembly and washer from the left side crankcase Note the positions of the alignment marks and washer for installing pur poses then release the cam stopper spring tension MD1239 CAUTION Care must be taken that the remover is fully threaded onto the rotor flywheel or damage may occur Section Table of Contents Manual Ta...

Page 51: ... Gears B Rotor Flywheel 1 Place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three cap screws securely MD1122 2 Install the starter motor and tighten the two cap screws to 8 ft lb 3 Install the shift detent cam making sure the washer is properly positioned MD1086 4 Install the cam stopper assembly 5 Install the gear shift shaft...

Page 52: ...on and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A V Belt Cover B Driven Pulley C Clutch Cover 1 If the engine is still in the frame remove the cap screw securing the brake pedal to the pivot shaft Account for a flat washer KC149A 2 Remove the cap screws securing the V belt cover to the clutch cover then...

Page 53: ...fixed drive face MD1094 7 Remove the nut holding the driven pulley assem bly then remove the driven pulley assembly MD1068 8 Using an impact screwdriver remove the three Phillips head cap screws holding the air intake plate Remove the air intake plate Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 54: ...E Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the cap screw holding the gear position switch onto the right side crankcase half KC324A 12 Remove the gear position switch Account for a spacer KC326A 13 Remove the one way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes MD1286 14 Remove the left hand threaded nut holding the c...

Page 55: ... driven gear Account for the drive pin and thrust washer MD1020 20 Remove three Phillips head screws holding the oil pump and remove the oil pump Account for two alignment pins MD1060 AT THIS POINT To service clutch components see Servicing Right Side Components sub section AT THIS POINT To service center crankcase components only pro ceed to Separating Crankcase Halves Section Table of Contents M...

Page 56: ...utch shoe assembly with the green dot or the word OUT SIDE 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 counterclockwise in respect to the clutch housing If the clutch shoe lock...

Page 57: ... inward and secure with a new snap ring NOTE Always use a new snap ring when install ing the oil pump driven gear MD1020 MD1019 3 Install the cam chain NOTE Keep tension on the cam chain to avoid damaging the crankcase boss 4 Place the pin into position install the oil pump drive gear and tighten the cap screw coated with red Loctite 271 to 63 ft lb MD1017 MD1018 5 Install the clutch shoe assembly...

Page 58: ...dure 8 Install two alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 9 Tighten the clutch cover cap screws to 8 ft lb MD1117 10 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 11 Place the driven pulley assembly into position and secure with the nut threads ...

Page 59: ...nd movable drive face onto the shaft KC127 15 Coat the threads of the nut with red Loctite 271 then making sure the splines of the clutch shaft protrude 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 16 Rotate the V belt and drive driven assemblies until the V belt is flush with the top of...

Page 60: ...kcase halves noting the position of the different sized cap screws for joining pur poses MD1006 MD1012 2 Using Crankcase 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...

Page 61: ...d gear from the output side of the gear cluster Remove the gear cluster and the inner shift fork together Account for snap ring gear and washer MD1328 6 Noting the position of the slot on the end remove the shift cam assembly Account for inner and outer washers KC325 7 Remove the counterbalance gear Account for the key 8 Remove the counterbalance shaft Section Table of Contents Manual Table of Con...

Page 62: ...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 tolerance Note the following chart Che...

Page 63: ...flection 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 Zero the indicator and push the small end of the connecting rod away from the dial indicator 3 Maximum deflection must not exceed specifica tions Measuring Connecting Rod Big End Side to Side ...

Page 64: ...and bearing 3 Remove the low driven gear washer then remove the low driven gear Account for the bushing and bearing 4 Remove the washer then remove the circlip secur ing the sliding dog Remove the sliding dog 5 Remove the high driven gear circlip then remove the high driven gear Account for the washer bushing and bearing Assembling 1 Place the high driven gear onto the countershaft making sure the...

Page 65: ...pply red Loctite 271 to the threads of the output shaft Install and tighten the nut 59 ft lb Using a punch peen the nut MD1333 3 Apply a liberal amount of oil to the crankshaft bearing Using a propane torch heat the bearing until the oil begins to smoke then slide the crank shaft assembly into place MD1334 NOTE If heating the bearing is not possible the crankshaft can be installed using a cranksha...

Page 66: ...r and inner shift fork While holding the gear cluster in place install the washer gear and snap ring MD1032 MD1198 8 Install the outer shift fork and the shift fork shaft MD1327 9 Install the input driveshaft MD1326 10 Install the washer spacer sleeve and reverse idler gear MD1357 Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www...

Page 67: ...nly 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 case to case pattern tighten the 8 mm cap screws 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 case to case pattern tighten the 6 mm cap s...

Page 68: ...tion switch connectors then attach the engine ground cable and starter cable and secure with cap screws and nuts Tighten to 8 ft lb KC228C KC228B 6 Set the inlet air silencer into the frame then install the exhaust pipe using a new exhaust pipe seal and grafoil seal Tighten the cap screws evenly to 20 ft lb and install the muffler retainer springs KC237 Section Table of Contents Manual Table of Co...

Page 69: ...etor boot and tighten all hose clamps securely KC254 9 Install the shift rod onto the shift arm with bushing and flat washer and secure with an E clip then connect the speedometer sensor plug KC255 KC248 10 Connect the oil temperature connector and cooling fan connector then using new O rings install the oil fittings onto the crankcase and secure with the cap screws Tighten to 8 ft lb Section Tabl...

Page 70: ... Install the front body panel front rack and foot wells see Steering Frame 14 Pour the appropriate quantity and grade oil into the crankcase then connect the negative battery cable and move the ATV outside to a well ventilated area 15 Start the engine and allow the engine to warm up while checking for oil leaks then shut the engine off and check the oil level Add oil as required Section Table of C...

Page 71: ...move the left footwell footrest and footwell support assembly then drain the coolant into a suitable container FI530A 3 From the left side remove the gear position switch connector A and the speed sensor connector B FI525A 4 Drain the engine oil into a suitable container 5 Remove the gas tank see Section 4 then remove the air inlet tube from the throttle body and air inlet tube FI691A 6 Remove the...

Page 72: ...he starter motor and the engine ground cable from the starter mounting flange FI523A FI533A 11 Remove the screens securing throttle arm cover to the throttle body then loosen the throttle cable jam nut and remove the throttle cable FI536A 12 Remove the cap screws securing the exhaust pipe to the cylinder head then remove the springs securing the muffler to the exhaust pipe 13 Remove the muffler an...

Page 73: ... 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 securing the two tappet covers Remove the two tappet covers Account for the O rings FI603 NOTE Keep the mounting hardware with the cov ers for assembly purposes 2 Remove the cylinder head cover cap screws No...

Page 74: ...ing purposes drop the sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cylinder head Account for an alignment pin NOTE Loop the chain over the cylinder and secure it to keep it from falling into the crankcase FI620 FI617A 7 Remove the cam chain tensioner pivot bolt and remove the chain tensioner then remove the two nuts securing the cylinder head to ...

Page 75: ... 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 AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section AT THIS POINT To inspect cam chain guide see Servicing Top Side Components sub section Section Table of Contents Manual T...

Page 76: ... inspect valve seats valve stems valve faces and valve stem ends for pits burn marks or other signs of abnormal wear NOTE Whenever a valve is out of tolerance it must be replaced Cleaning Inspecting Cylinder Head Cover NOTE If the cylinder head cover cannot be trued the cylinder head assembly must be replaced 1 Wash the cylinder head cover in parts cleaning solvent AT THIS POINT To service cylinde...

Page 77: ...the valve seal and the lower remaining spring seat Discard the valve seal CC134D CC136D NOTE The valve seals must be replaced 3 Remove the valve springs then invert the cylinder head and remove the valves Measuring Valve Stem Runout 1 Support each valve stem end with the V Blocks then check the valve stem runout using a dial indi cator ATV 1082 2 Maximum runout must not exceed specifications Measu...

Page 78: ...be taken to a qualified machine shop for ser vicing Measuring Rocker Arm Inside Diameter 1 Using a dial calipers measure the inside diameter of the rocker arm 2 Acceptable inside diameter range must be within specifications Measuring Rocker Arm Shaft Outside Diameter 1 Using a micrometer measure the outside diameter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifi...

Page 79: ... 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 installing new rings install as a complete set only Cleaning Inspecting Piston Ring Grooves 1 Take an old piston ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge 2 Using the sharpened ring as a tool clean car...

Page 80: ...n above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measurement in step 1 The difference clearance must be within specifica tions 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 lo...

Page 81: ...ing 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 Honing Cyl inder in this sub section 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 Inspec...

Page 82: ...i ately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder CC390D 4 If any measurement exceeds the limit bore the cylinder and must be replaced Measuring Camshaft Runout NOTE If the camshaft is out of tolerance it must be replaced 1 Place the camshaft on a set of V blocks then posi tion the dial indicator contact point against the shaft and zero the indic...

Page 83: ... to cylinder head and valve cover clear ance CC145D 6 If clearance is excessive measure the journals of the camshaft CC287D NOTE If the journals are worn replace the cam shaft then measure the clearance again If it is still out of tolerance replace the cylinder head Inspecting Camshaft Spring Drive Pin 1 Inspect the spring and unloader pin for damage CF061A NOTE With the weight extended the unload...

Page 84: ...am 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 the two nuts securing the cylinder to the right side crankcase half NOTE The two cylinder to crankcase nuts will be tightened in step 9 FI622A C Cylinder Head Camshaft D Cylinder Head Cover Rocker Arms NOTE Steps 1 4 in the preceding sub section mus...

Page 85: ...on is at top dead center 11 While holding the cam chain to the front install the rear cam chain tensioner guide into the cylin der 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 pis ton place the camshaft in position and verify that the timing mark on the magneto is visible through...

Page 86: ... 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 securing the sprocket and tab washer to the cam shaft 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 securi...

Page 87: ...maining cap screws Tighten only until snug MD1261 26 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 25 to 8 ft lb 27 Adjust valve tappet clearance see Section 2 28 Place the two tappet covers with O rings into posi tion then install and tighten the cap screws to 8 ft lb FI602 29 Install the spark plug and tighten securely then install the timi...

Page 88: ...two seal wash ers FI543 5 Remove the cap screws securing the magneto cover to the crankcase Note the location of the two internal 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 s...

Page 89: ... 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 snap ring securing the output drive gear to the output shaft and remove the ...

Page 90: ...e conditions exist replace the starter clutch assembly FI572 REPLACING STARTER CLUTCH ASSEMBLY 1 Remove the cap screws securing the one way clutch assembly to the flywheel then remove from the flywheel FI570 2 Thoroughly clean the rotor flywheel then install the new one way clutch and secure with the cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a cri...

Page 91: ...on sensor 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 assembly and secure with three cap screws using a drop of red Loctite 271 on each Tighten to 8 ft lb 4 Place the stato...

Page 92: ...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 securely 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 washer ...

Page 93: ...erent lengthed 6 mm cap screws and the location of the two internal cap screws tighten 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 and a gasket on the magneto cover then install the water pump hous ing assembly Tighten the cap screws to 8 ft lb FI541A FI539 12 Install the w...

Page 94: ...cap screws securing the V belt cover to the clutch cover then slide the brake pedal out ward and remove the V belt cover Account for two alignment pins and a gasket KC142A 3 Mark the movable drive face and the fixed drive face for installing purposes then remove the nut holding the movable drive face onto the crank shaft MD1033 4 Remove the movable drive face and spacer Account for the movable dri...

Page 95: ...r intake plate MD1092 9 Remove the cap screws holding the clutch cover onto the right side crankcase half Note the posi tions of the different lengthed cap screws for installing purposes 10 Using a rubber mallet loosen the clutch cover then pull it away from the right side crankcase half Account for two alignment pins and gasket MD1115 D Centrifugal Clutch Assembly E Oil Pump Drive Gear F Oil Pump...

Page 96: ...16 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 MD1019 CAUTION Care must be taken when removing the nut it has left hand threads Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www my...

Page 97: ...OTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary INSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoe for uneven wear chips cracks or discoloration 2 Inspect the depth of the grooves in the clutch shoes If any shoe is worn to the bottom of the groove replace the complete set AT THIS POINT To service clutch components see Servic...

Page 98: ...n respect to the clutch housing If the clutch shoe locks up or turns in both direc tions 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 PULL...

Page 99: ...OTE Always use a new snap ring when install ing the oil pump driven gear MD1020 MD1019 5 Install the cam chain NOTE Keep tension on the cam chain to avoid damaging the crankcase boss 6 Place the pin into position install the oil pump drive gear and tighten the cap screw coated with red Loctite 271 to 63 ft lb MD1017 MD1018 7 Install the clutch shoe assembly on the crankshaft then install the flang...

Page 100: ...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 Loc tite 271 Tighten to 147 ft lb MD1068 KC134 13 Slide the fixed drive face assembly onto the front shaft 14 Spread the faces of the driven pulley by threading a V belt cover cap screw into the f...

Page 101: ...blies 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 Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Complete Removing procedures for Top Side Left Side and Right Side m...

Page 102: ...ssemblies 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 assembly A noting the location of the front and rear bearing loca...

Page 103: ...ng 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 Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mym...

Page 104: ...el gear back and forth note the maximum backlash reading on the gauge 5 Acceptable backlash range is 0 05 0 33 mm 0 002 0 013 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 ...

Page 105: ... must be replaced Measuring Connecting Rod Small End Inside Diameter 1 Insert a snap gauge into the upper connecting rod small end bore then remove the gauge and mea sure it with micrometer CC290D 2 Maximum diameter must not exceed specifica tions 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 Posit...

Page 106: ...d following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the outside edge of one web to the outside edge of the other web ATV 1017 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 CAUTION Care should be taken to support the ...

Page 107: ... 4 Remove the splined washer then remove the cir clip securing the high low sliding dog Remove the sliding 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 Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 6...

Page 108: ...splined washer 8 FI668A 3 Install the low 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 Section Ta...

Page 109: ...hten 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 bearing Using a propane torch heat the bearing until the oil begins to smoke then slide the crank shaft assembly into place MD1334 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft installer 4 Rotate the crankshaft so the coun...

Page 110: ...652A 7 Place the shift forks into position 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 crank case FI653A FI655A 9 Install the input driveshaft Section Table of Contents Manual Table of Contents For Disco...

Page 111: ...es then install the center carrier bearing alignment C ring FI660A FI659A FI661A Joining Crankcase Halves 1 Verify that the two alignment pins A are in place and that both case halves are clean and grease free Apply Three Bond Sealant to the mating surfaces Place the right side half onto the left side half Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 67...

Page 112: ... 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 Installing Engine Transmission 1 From the left side place the engine into the frame rear of engine first tilting the rear up to allow cylinder head to clear frame 2 With engine moved rearward engage the splines of the front driveline into ...

Page 113: ...22A 10 Place the air filter assembly into position and con nect the crankcase breather securing with the clamp then connect the front air inlet duct and secure with a hose clamp 11 Install the harness connector onto the coil and install the spark plug cap 12 Connect the air ducts to the CVT housing and tighten the clamps securely then connect the air inlet tube to the throttle body and secure with...

Page 114: ...rottle Body 425 4 9 Throttle Cable Free Play 4 10 Engine RPM Idle 4 10 Gas Tank 4 10 Oil Filter Oil Pump 4 12 Testing Oil Pump Pressure 4 12 Oil Cooler 350 4 12 Liquid Cooling System 425 4 13 Electric Fuel Pump Fuel Level Sensor 425 4 15 Troubleshooting 350 4 17 Troubleshooting 425 4 18 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 115: ...approxi mately 70 F measure plunger extension Mea surement A should be 18 6 19 1 mm KC328B 3 Connect Electric Choke Test Harness to the choke connector and a suitable 12 DC volt power supply for 2 3 minutes Disconnect the power and mea sure plunger extension Measurement B should be 22 1 23 4 mm KC328C 4 If the choke is damaged or the measurements are not within specifications the choke must be rep...

Page 116: ...rburetor can now be removed for service WARNING Whenever any maintenance or inspection is per formed on the fuel system during which there may be fuel leakage there should be no welding smoking open flames etc in the area KEY 1 Cover 2 Screw 3 Spring 4 Vacuum Piston 5 Spring Seat 6 Jet Needle 7 Needle Jet 8 Jet Holder 9 Main Jet 10 Slow Jet 11 Starter Jet 12 Float Valve 13 Clip 14 Float 15 Float P...

Page 117: ...ring the pump hous ing Account for the diaphragm assembly spring and U ring in the housing CC748 4 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring KC0022A KC0063A 5 Remove the float pin KC0024A 6 Lift the float assembly from the carburetor Account for the float valve and clip Section Table of Contents Manual Table of Contents For Discount A...

Page 118: ... water Rinse thoroughly 4 Dry all components with compressed air only making sure all holes orifices and channels are unobstructed 5 Inspect the carburetor body for cracks nicks stripped threads and any imperfections in the cast ing 6 Inspect the vacuum piston diaphragm for cracks imperfections in the casting or cracks and tears in the rubber 7 Inspect float for damage 8 Inspect gasket and O rings...

Page 119: ... seated then turn it counterclockwise the recommended number of turns as an initial setting NOTE Note the locations of the jets and holder during assembling procedures CC761A 3 Install the starter jet and slow jet Tighten securely KC0032A 4 Install the main jet into the needle jet holder and tighten securely then install the needle jet and needle jet holder assembly into the carburetor and tighten...

Page 120: ...onto the carburetor then secure the assembly with the pump housing and three screws Tighten securely CC748 8 Place the jet needle spring seat and spring into the vacuum piston then place the assembly down into the carburetor CC746 9 Place the top cover into position then secure with the Phillips head screws Tighten securely CAUTION It is important to press down on the pump housing until it contact...

Page 121: ...he jam nut securely and install the throttle arm cover KC258A KC266 3 Install the carburetor onto the engine making sure the alignment lug on the carburetor is between the two tabs on the air intake pipe then tighten the clamp securely KC245A KC256A 4 Connect the intake air housing and tighten all clamps and mounting hardware securely Section Table of Contents Manual Table of Contents For Discount...

Page 122: ...ing rearward FI691A 3 Disconnect the MAP IAT sensor connector ISC connector and TPS connector then loosen the clamp securing the throttle body to the intake man ifold boot and slide the throttle body out FI528A 4 Remove the throttle arm cover and loosen the throttle cable jam nut then disconnect the throttle cable and remove the throttle body INSTALLING 1 Connect the throttle cable to the throttle...

Page 123: ...uring the gas tank to the frame and using a suitable block support the rear of the tank then remove the clamp securing the gasline hose and remove the hose from the gas tank valve 350 On the 425 disconnect the gas line connector from the fuel pump outlet KC241A 6 Using a suitable block hold the front body open and remove the gas tank to the rear Account for the heat shield KC260 WARNING Whenever a...

Page 124: ...he gas tank valve outlet Secure with a clamp 350 KC241A 3 Remove all blocking and secure the gas tank with the cap screw Tighten securely then connect the gasline connector to the fuel pump outlet 425 KC225A 4 Secure the rear of the front body to the frame with the cap screws A and tighten securely then install the gas tank cover and secure with the rein stallable rivets B KC219A 5 Install the sid...

Page 125: ...e oil pressure must read 1 1 1 7 kg cm2 16 25 psi on the 350 or 0 6 0 7 kg cm2 8 5 17 psi on the 425 KC268 KC269 NOTE If the oil pressure is lower than specified check for low oil level defective oil pump or restricted oil cooler NOTE If the oil pressure is higher than specified check for clogged oil passage clogged oil filter or improper installation of the oil filter Oil Cooler 350 0743 004 REMO...

Page 126: ...nt for the grommets and collars 6 Remove the fan fan shroud assembly from the radiator Cleaning and Inspecting NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Flush the radiator with water to remove any con taminants 2 Inspect the radiator for leaks and damage 3 Inspect all hoses for cracks and deterioration 4 Inspect all fasteners and grommets for...

Page 127: ...mo stat housing then secure the thermostat housing to the mounting bracket with the two cap screws 2 Fill the cooling system to the recommended level with antifreeze Check for leakage WATER PUMP NOTE The water pump is a non serviceable component It must be replaced as an assembly Removing 1 Remove the radiator cap then remove the water pump drain and drain the coolant FI530A 2 Drain the oil from t...

Page 128: ...ar rack from behind 5 Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire then turn the ignition switch to the ON position The meter should read battery voltage If battery voltage is indicated and the fuel pump does not run replace the pump assembly If no battery voltage is indi cated check the ECU and the vehicle tilt...

Page 129: ...16 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 4 To replace the fuel level sensor use the following procedure A Disconnect the two wire connector A then press the fuel level sensor toward the top of the fuel pump to release it from the mounting slot B FI460A B Engage the tabs C of the fuel level...

Page 130: ...r jet obstructed 2 Starter jet passage obstructed 3 Carburetor leaking air 4 Gas contaminated 1 Clean jet 2 Clean passage 3 Replace gasket 4 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 Slow jet obstructed loose 2 Slow jet outlet obstructed 3 Low speed fuel screw setting incorrect 4 Float height incorrect 5 TPS out of adjustment 1 Clean tighten jet...

Page 131: ...m Idling or low speed impaired Condition Remedy 1 TPS out of adjustment 1 Adjust TPS Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 1 Decrease RPM speed Section Table of Contents Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 132: ... 5 Ignition Coil 5 6 Speed Sensor 5 7 Ignition Switch 5 7 Handlebar Control Switches 5 8 Front Drive Selector Switch 425 5 9 Front Drive Selector Actuator 425 5 9 Gear Position Switch 350 5 9 Stator Coil 5 10 Starter Relay 5 11 Starter Motor 5 11 CDI Unit 350 5 12 Regulator Rectifier 5 12 Lights 5 12 Ignition Timing 5 13 Diagnostic Trouble Codes DTC 425 5 14 Tilt Sensor 425 5 15 Throttle Position ...

Page 133: ...10 Description p n Fluke Model 73 Multimeter 0644 191 Fluke Model 77 Multimeter 0644 559 MaxiClips 0744 041 Peak Voltage Reading Adapter 0644 307 350 Ignition Timing 10 BTDC 1500 RPM Spark Plug Type NGK CR8E Spark Plug Gap 0 7 0 8 mm 0 028 0 032 in Spark Plug Cap 4000 6000 ohms Ignition Coil primary Resistance secondary Less than 1 ohm terminal to terminal 2900 3400 ohms high tension plug cap remo...

Page 134: ... type of meter is used readings may vary due to internal circuitry When trou bleshooting a specific component always verify first that the fuse s are good that the bulb s are good that the connections are clean and tight that the battery is fully charged and that all appropriate switches are activated NOTE For absolute accuracy all tests should be made at room temperature of 68 F Accessory Recepta...

Page 135: ...thermometer should be allowed to touch the bottom of the con tainer or inaccurate readings will occur Use wire holders to suspend switch and thermometer 733 554C 3 On the oil temperature switch when the oil tempera ture reaches 160 C 320 F the meter should read a closed circuit 4 On the oil temperature switch allow the oil to cool and when the temperature is at or just before a tem perature of 140...

Page 136: ...fuse motor or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good The connector should be checked for resistance RESISTANCE Fan Motor Connector 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the red wire then con nect the black tester lead to the black wire 3 The meter must show less than 1 ohm NOTE If the meter shows more...

Page 137: ...he power distribution module Relay function can be checked by switching relay positions The relays are interchangeable NOTE The module and wiring harness are not a service able component and must be replaced as an assembly Ignition Coil The ignition coil is on the frame above the engine To access the coil the left side panel must be removed RESISTANCE NOTE For these tests the meter selector should...

Page 138: ...ge lead V then connect the black tester lead to the ground lead G KC248A 3 Turn the ignition switch to the ON position 4 The meter must show greater than 5 0 volts 5 Leave the black tester lead connected then connect the red tester lead to the signal lead pin S 6 Slowly move the ATV forward or backward the meter must show 0 and 6 volts alternately NOTE If the sensor tests are within specifications...

Page 139: ... 2 Connect one tester lead to the brown black wire then connect the other tester lead to the lavender 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 one tester lead to the brown black wire then connect the other tester lead to the white wire 2 With the dimmer...

Page 140: ...nition switch in the OFF position connect the black tester lead to the black wire in the supply harness then connect the red tester lead to either orange wire in the supply harness 3 Turn the ignition switch to the ON position The meter must show 12 DC volts 4 Connect the red tester lead to the second orange wire in the supply harness The meter must show 12 DC volts 5 Connect the red tester lead t...

Page 141: ...est between the three black wires for a total of three tests 3 With the engine running at the specified RPM all wire tests must show 60 AC volts NOTE If both charging coil tests failed check all connections etc and test again If no voltage is present replace the stator assembly RESISTANCE Charging Coil 1 Set the meter selector to OHMS position 2 Test between the three black wires for a total of th...

Page 142: ...l slide the boot away NOTE The ignition switch must be in the ON posi tion the emergency stop switch in the RUN position and the shift lever in the NEUTRAL position 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the starter terminal then connect the black tester lead to ground 3 With the starter button depressed the meter must show approximately 10 0 DC volts ...

Page 143: ...ect 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 volts NOTE If voltage rises above 15 5 DC volts the regula tor is faulty or a battery conn...

Page 144: ...nect the black tester lead to the black wire then connect the red tester lead to the green yellow wire 3 The meter must show battery voltage NOTE If the meter does not show voltage inspect bulb fuses wiring harness connectors and switches BACK UP LIGHTS The connectors are located on the rear frame supports attached by a metal tab They may be released from the frame by depressing the release with a...

Page 145: ...08 F2 MAP Sensor Circuit High SP P0112 F3 IAT Sensor Circuit Low SG P0113 F3 IAT Sensor Circuit High Open P0114 F3 IAT Sensor Circuit Intermittent P0116 F4 ECT Sensor Circuit Range Performance P0117 F4 ECT Sensor Circuit Low SG P0118 F4 ECT Sensor Circuit High Open SP P0119 F4 ECT Sensor Circuit Intermittent P0121 G3 TPS Range Performance P0122 G3 TPS Circuit Low SG P0123 G3 TPS Circuit High P0219...

Page 146: ... Connect the three wire plug to the sensor then remove the mounting screws securing the sensor to the frame KC339E 2 Install the needle adapters to the multimeter leads then select DC Voltage on the multimeter 3 Connect the red tester lead to the blue brown wire B and the black tester lead to the pink black wire A then turn the ignition switch ON and observe the meter The meter should read 0 3 1 5...

Page 147: ...the ignition switch to the OFF position 5 Select the OHMS position on the meter then per form the following resistance tests on the TPS A Pin B to ground infinity open circuit B Pin A to pin B approximately 1 22k ohms throttle closed C Pin A to pin B approximately 4 5k ohms throttle full open D Pin A to pin C approximately 5 5k ohms PR535A NOTE If any meter reading is not as specified replace or a...

Page 148: ... 1 Place the TPS into position on the throttle body and secure with the screw Do not tighten at this time 2 Connect the TPS Multi Analyzer Harness connec tor 8 to the TPS then connect the harness to the TPS Analyzer Tool FI672 3 Using a multimeter connect the black tester lead to the black socket GND on the analyzer and the red tester lead to the white socket VAR then select the Voltage position F...

Page 149: ...or rectifier Problem Alternator charges but charging rate is below the specification Condition Remedy 1 Lead wires shorted open loose at terminals 2 Stator coils grounded open 3 Regulator rectifier defective 4 Electrolyte low 350 5 Battery defective 1 Repair tighten lead wires 2 Replace stator coils 3 Replace regulator rectifier 4 Add distilled water 5 Replace battery Problem Alternator overcharge...

Page 150: ...discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Specific gravity too low 350 3 Charging system not charging 4 Battery overcharged damaged 5 Battery short circuited 1 Replace battery 2 Charge battery add distilled water 3 Check alternator regulator rectifier circuit connections 4 Replace battery correct charging system 5 Replace battery Problem Battery polarity reversed Conditi...

Page 151: ...r 425 6 2 Front Differential 6 3 Drive Axles 6 14 Rear Gear Case 6 15 Hub 6 16 Hydraulic Brake Caliper 6 17 Troubleshooting Drive System 6 20 Troubleshooting Brake System 6 20 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 152: ...uns constantly or makes squealing or grinding sounds the actuator must be replaced REMOVING 1 Disconnect the connector on the actuator harness 2 Remove the mounting cap screw from the drive shaft side of the actuator KC293A 3 Remove the mounting cap screw from below the actuator on the suspension side KC294A 4 Loosen but do not remove the mounting cap screw at the front of the actuator then slide ...

Page 153: ...fferential 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 the cotter pin securing the hex nut then remove the hex nut 6 Release the brake lever loc...

Page 154: ...and remove the differential from the frame KC291A Disassembling Input Shaft NOTE This procedure can be performed on a rear gear case however some components may vary from model to model The technician should use discretion and sound judgment 1 Remove the cap screws securing the front drive actuator and remove the actuator then remove the cap screws securing the pinion housing CD102 2 Using a rubbe...

Page 155: ...Remove the snap ring securing the input shaft bearing then place the pinion housing in a press and remove the bearing AF983 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 AF993 Section Table of Contents Manual Table of Content...

Page 156: ... O ring lubricated with grease install the front drive actuator and secure with the cap screws 6 Place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to 18 ft lb CD103 Disassembling Pinion Gear NOTE This procedure can be performed on a rear gear case 1 On the 425 remove the cap screws securing the pinion housing then remove the housin...

Page 157: ...mm Internal Hex Socket remove the lock collar secur ing the pinion gear assembly NOTE On a front differential the lock collar has right hand threads On a rear gear case the lock collar has left hand threads CC875 CC876 6 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing CAUTION Failure to completely remove the staked material from the lock coll...

Page 158: ... any other shimming 1 Install the existing shim or a 0 051 0 055 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 GC059A 3 Install the bearing flange onto the gear c...

Page 159: ...ult in quieter gear operation GC071A Ring Gear End Play After correcting backlash ring gear end play can be adjusted To adjust end play use the following proce dure 1 Secure the gear case in a holding fixture with the cover side up then install a dial indicator contact ing the ring gear axle flange GC065 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End pl...

Page 160: ...ness 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 1 and 2 using thicker clearance too great or thinner clearance too small until correct specification is reached Assembling Differential ...

Page 161: ...small amount of oil to the gasket then install the gasket 425 CC893 6 Place the input shaft assembly onto the gear case housing then secure with the existing cap screws Tighten to 18 ft lb CD103 CD110 Removing Needle Bearing NOTE Removing the needle bearing is rarely necessary Avoid removing the needle bearing unless the bearing is clearly damaged NOTE This procedure can be performed on a rear gea...

Page 162: ...ousing GC045A 3 Install the pinion shaft and secure with a new 48 mm lock collar Tighten to 125 ft lb CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock collar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case ...

Page 163: ...e side INSTALLING DIFFERENTIAL 1 Align the input flange with the front output flange then place the differential into position on the frame and install the cap screws and nuts Tighten to 38 ft lb KC291A 2 Install the cap screws securing the flange couplers together and tighten to 20 ft lb AG925 3 Install the front axles see Drive Axles in this sec tion CAUTION Make sure the tool is free of nicks o...

Page 164: ...onary pull the top of the knuckle out and down until it is free of the drive axle KC285 7 Place a drain pan under the ATV to contain any oil leakage then pull out sharply on the axle to dis lodge the splines from the gear case Remove the axle 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 t...

Page 165: ...knuckle then insert the upper A arm ball joint into the steering knuckle Secure with a cap screw tightened to 35 ft lb 2 Slide the hub w brake disc into position in the steering knuckle followed by a washer and hex nut Tighten finger tight at this time 3 Install the brake caliper on the steering knuckle Tighten to 20 ft lb then pump up the hand brake lever and engage the brake lever lock 4 Tighten...

Page 166: ...omponents 2 Inspect all threads for stripping or damage 3 Inspect the brake disc for cracks or warping 4 Inspect the hub for pits cracks loose studs or spline wear INSTALLING 1 Secure the brake disc to the hub with the four cap screws coated with blue Loctite 243 Tighten to 15 ft lb 2 Apply grease to the splines in the hub 3 Install the hub assembly onto the shaft 4 Secure the hub assembly with th...

Page 167: ...press the caliper holder against the caliper opposite the O ring side and remove the outer brake pad then remove the inner brake pad NOTE If brake pads are to be returned to service do not allow brake fluid to contaminate them PR237A PR238 5 Remove the caliper holder from the caliper and discard the O ring WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic ...

Page 168: ...ds see Periodic Maintenance 3 Inspect the brake caliper housings for scoring in the piston bores chipped seal ring grooves or signs of corrosion or discoloration 4 Inspect the piston surface for scoring discolor ation 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...

Page 169: ...der toward the cali per and install the inner brake pad then install the outer pad PR238 PR239 6 Place the brake caliper assembly into position and secure with new patch lock cap screws Tighten the caliper to 20 ft lb 7 Place a new crush washer on each side of the brake hose fitting and install it on the caliper Tighten to 20 ft lb CAUTION If brake pads become contaminated with brake fluid they mu...

Page 170: ... Sliding dogs shaft fork worn damaged 8 Front drive axle worn damaged 9 Front drive axle serration worn damaged 1 Replace gear s 2 Replace shaft 3 Replace 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 Maste...

Page 171: ...E OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 2 Rear A Arms 7 3 Wheels and Tires 7 4 Troubleshooting 7 6 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 172: ...ust be replaced INSTALLING 1 Place bushings and sleeves where appropriate into shock eyelet then install shock with cap screws and nuts Tighten all nuts to 35 ft lb 2 Remove the ATV from the support stand Front A Arms REMOVING 1 Secure the ATV on a support stand to elevate the front wheels then remove the wheels 2 Remove the cotter pin from the nut Discard the cotter pin 3 Remove the nut securing ...

Page 173: ...ighten the cap screws to 35 ft lb 5 Install the knuckle assembly onto the ball joints and secure with cap screws Tighten to 35 ft lb 6 Apply grease to the hub and drive axle splines then install the hub assembly onto the drive axle 7 Secure the hub assembly with the nut Tighten only until snug 8 Secure the brake caliper to the knuckle with the two patch lock cap screws Tighten to 20 ft lb 9 Secure...

Page 174: ...the brake caliper to the knuckle with the two cap screws right side only Tighten the cali per to 20 ft lb 7 Compress the hand brake lever and engage the brake lever lock then secure the hub nut from step 5 to the drive axle Tighten to 200 ft lb 8 Install a new cotter pin and spread the pin to secure the nut 9 Secure the shock absorber to the frame with a cap screw and new lock nut Tighten to 35 ft...

Page 175: ...punctures NOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Be sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe in and toe out and adjust as necessary see Steering Frame 4 Test drive the ATV on a dry level surface and note any pulling to the left or right durin...

Page 176: ...2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Rear 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 R...

Page 177: ...8 3 Steering Knuckles 8 4 Measuring Adjusting Toe Out 8 5 Front Rack 8 6 Front Bumper Assembly 8 6 Front Body Panel Fender 8 7 Exhaust System 8 8 Rear Body Panel Rack 8 9 Seat 8 11 Troubleshooting 8 11 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 178: ... two handlebar caps KC0058 3 Remove the cap screws securing the upper steer ing post to the frame Account for the housing cap outer housing and inner housing KC307A 4 Remove the cotter pins from the inner tie rod ends then remove the nuts and disconnect the inner tie rod ends KC184A NOTE If tie rods are to be completely removed remove the outer tie rod ends from the knuckles at this time 5 Remove ...

Page 179: ...rt then with the housing cap in place secure with the cap screws Tighten to 20 ft lb KC307A 3 Using red Loctite 271 on the threads install the tie rod ends into the lower steering post arm and tighten to 30 ft lb then install new cotter pins KC184A 4 Place the handlebar and caps in place on the steer ing post and with the handlebar correctly posi tioned tighten the cap screws to 20 ft lb KC0058 5 ...

Page 180: ...from the nut 3 Remove the nut securing the hub 4 Remove the brake caliper 5 Remove the hub assembly 6 Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then remove the knuckle 9 Remove the snap ring from the knuckle then remove the bearing PR287A PR28...

Page 181: ...ap screws Tighten to 20 ft lb KC283 8 Pump the hand brake lever then engage the brake lever lock 9 Secure the hub nut from step 6 to the shaft Tighten to 200 ft lb 10 Install a new cotter pin and spread the pin to secure the nut 11 Install the wheel then using a crisscross pattern tighten to 40 ft lb 12 Remove the ATV from the support stand Measuring Adjusting Toe Out 1 Thoroughly wash the ATV to ...

Page 182: ...just both tie rods equally until within specifications 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 Front Rack REMOVING 1 Remove the cap screws and lock nuts securing the rack to the frame and front fender panel 2 Remove the front rack from the ATV CLEANING AND INSPECTING NOTE Whenever a part is wor...

Page 183: ...rom step 1 to 20 ft lb then tighten the cap screws securely Front Body Panel Fender REMOVING 1 Remove the seat and both side panels 2 Remove the front rack then disconnect the head light running light connectors located on the frame KC224 NOTE Use a small screwdriver to disengage the tab connector allowing the connector assembly to be removed from the frame KC223 3 Remove the cap screws A then rem...

Page 184: ...der panel onto the ATV With the front rack in place loosely install the front rack hardware 2 Connect the electrical connectors under the elec tric panel then connect the light connectors and attach onto the frame KC210G KC224 3 Install the screws securing the front body to the front body supports then install the left side and right side footwell fasteners Do not tighten at this time 4 Place the ...

Page 185: ...he two exhaust springs Rear Body Panel Rack REMOVING 1 Remove the rear rack then remove two cap screws securing the rear body panel fender to the side frame and the cap screws securing the rear fenders to the footwells KC317A KC316 2 Disconnect the battery negative cable first and remove from the battery compartment then dis connect the starter relay wires and route the wiring out of the compartme...

Page 186: ...lace the rear body panel fender in place on the ATV then secure with the cap screws on the side frame and the rear rack assembly Tighten all fas teners securely KC317A KC320A 2 Connect the light connectors and secure to the frame then install the battery starter relay and auxiliary brake Connect all wiring making sure to connect the positive cables first KC279 KC322 3 Secure the rear fenders to th...

Page 187: ...ose 6 Tires defective incorrect 7 A arm bushings damaged 8 Bolts nuts frame loose 1 Adjust pressure 2 Replace wheel s 3 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 ...

Page 188: ...RS TABLE OF CONTENTS Controls Indicators 9 2 Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 2 LCD Gauge 9 3 Manual Table of Contents For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 189: ...rake 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 and bolt for cracks and deterioration and the condition of the fittings threaded and compression INSTALLING 1 Position the brake housing on the handlebar Secure with clamp screws then tighten securely 2 Using two new crush washers connect the ban...

Page 190: ...es of the throttle control onto the handlebar and secure with the two machine screws ADJUSTING To adjust throttle cable free play see Periodic Mainte nance LCD Gauge REPLACING 1 Remove the electric panel and disconnect the LCD gauge connector then remove three mounting screws two in front and one in back of gauge and remove the gauge KC210G KC323A 2 Install the new gauge and secure with the mount ...

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