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Arctic Cat 400TRV 2011, Service Manual

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Arctic Cat 400TRV 2011 Service Manual Download Page 134

8-9

8

AF789D

9. Measure the distance between the marks (at a height

parallel to the belly panel) at the front side; then

record the measurement.

10. Push the ATV forward until the marks are parallel to

the belly panel on the back side; then measure the

distance between the marks.

11. The difference in the measurements must show

1/8-1/4 in. toe-out (the front measurement 1/8-1/4 in.

more than the rear measurement).

12. If the difference in the measurements is not within

specifications, adjust 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 worn excessively,

cracked, or damaged in any way, replacement is nec-
essary.

1. Clean all rack components using a pressure washer.

2. Inspect all welds for cracking or bending.

3. Inspect threaded areas of all mounting bosses for

stripping.

4. Inspect for missing decals and/or reflectors.

INSTALLING

1. Place the rack into position on the frame and front

fender panel. Install the cap screws and lock nuts and

finger-tighten only.

2. Install the two cap screws and lock nuts securing the

rack to the fenders. Tighten all hardware securely.

Front Bumper Assembly

REMOVING

1. Remove the two flange bolts and lock nuts securing

the upper bumper supports to the bumper.

2. Remove the through-bolt and lock nut securing the

bumper to the frame; then remove the bumper.

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-
essary.

1. Clean all bumper components with parts-cleaning

solvent.

2. Inspect all welds for cracking or bending.

INSTALLING

1. Place the front bumper assembly into position and

install the through-bolt. Start the lock nut and fin-

ger-tighten only.

2. Install the two flange bolts and lock nuts on the

upper supports. Tighten all hardware securely.

Front Body Panel/Side 

Panels

REMOVING

1. Remove the reinstallable rivets securing the radiator

access cover and remove the cover; then remove four

reinstallable rivets securing the steering post cover

and remove the cover.

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

www.mymowerparts.com

Summary of Contents for 400TRV 2011

Page 1: ...ation The 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 info...

Page 2: ...ators 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 Note To navigate through this manual use the PAGE UP PAGE DOWN buttons on the keyboard click on the Table of Contents bookmarks on the left side of the screen or click the blue text below To return to this page click the Manual Table of Contents button at the bottom of each page Click on th...

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

Page 4: ...ame 50 68 Knuckle Ball Joint 35 47 Shock Absorber Frame Upper A Arm 50 68 Knuckle A Arm 50 68 SUSPENSION COMPONENTS Rear Part Part Bolted To Torque ft lb N m Shock Absorber Upper Frame 35 47 Shock Absorber Lower Lower A Arm 20 27 A Arm Frame 35 47 Knuckle A Arm 35 47 DRIVE TRAIN COMPONENTS Front Differential Frame Differential Bracket 38 52 Pinion Housing Differential Housing 23 31 Differential Ho...

Page 5: ...hane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent 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 specifically formulated for use in this Arctic Cat engine Although Arct...

Page 6: ...e Install the air filter and housing cover 4 Drain the carburetor float chamber 5 Plug the exhaust hole in the exhaust system with a clean cloth 6 Apply light oil to the upper steering post bushing and plungers of the shock absorbers 7 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated ...

Page 7: ... replace as necessary 7 Tighten all nuts bolts cap screws and screws mak ing sure all calibrated nuts cap screws 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 necessary CAUTION The ignition switch must be in the OFF position prior to in...

Page 8: ... 4 Spark Plug 2 5 Muffler Spark Arrester 2 5 Engine Transmission Oil Filter Strainer 2 6 Front Differential Rear Drive Lubricant 2 7 Nuts Bolts Cap Screws 2 8 Headlights Taillight Brakelight 2 8 Shift Lever 2 9 Frame Welds Racks 2 10 Hydraulic Brake Systems 2 10 Burnishing Brake Pads 2 12 Checking Replacing V Belt 2 12 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerpart...

Page 9: ...er Spark Arrester C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R Carburetor Float Chamber D Engine Idle RPM I I A Engine Transmission Oil Level I A Engine Transmission Oil Filter R R R R R Oil Strainer I I C Front Differential Rear Drive Lubricant I I R 4 Yrs Tires Air Pressure I I R Steering Components I I I R V Belt I l R Suspension Ball joint boots drive axle boots front and rear tie...

Page 10: ... the air filter housing cover and the air fil ter frame assembly 3 Remove the foam element from the frame making sure not to tear the element CD747 4 Fill a wash pan larger than the element with a non flammable solvent then dip the element in the solvent and wash it NOTE Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat 5 Squeeze the element by pressing it between the p...

Page 11: ...e valve adjuster handle in place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in Feeler Gauge Procedure sub section 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...

Page 12: ...iced or the carburetor may need to be adjusted To maintain a hot strong spark keep the plug free of car bon ATV 0051 Adjust the gap to 0 7 0 8 mm 0 028 0 032 in for proper ignition Use a feeler gauge to check the gap ATV0052C When installing the spark plug be sure to tighten it securely A new spark plug should be tightened 1 2 turn once the washer contacts the cylinder head A used spark plug shoul...

Page 13: ...ng each time the filter is replaced 7 Install the engine drain plug and tighten to 20 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug 8 Start the engine while the ATV is outside on level ground and allow it to idle for a few minutes 9 Turn the engine off and wait approximately one min ute 10 Remove the oil level stick and wipe it wi...

Page 14: ...ap screws Tighten securely CC091D 6 Install the belly panel Front Differential Rear Drive Lubricant When changing the lubricant use approved SAE 80W 90 hypoid gear lube To check lubricant remove the fill plug the lubricant level should be 1 in below the threads of the plug If low add SAE approved 80W 90 hypoid gear lubricant as nec essary To change the lubricant use the following procedure 1 Place...

Page 15: ...procedure 1 Rotate the bulb assembly counterclockwise and remove from the headlight housing then disconnect from the wiring harness 2 Connect the new bulb assembly to the wiring harness connector then insert into the headlight housing and rotate fully clockwise To replace the taillight brakelight bulb use the following procedure 1 Turn the bulb socket assembly counterclockwise and remove from the ...

Page 16: ... the transmission into the R position The reverse gear indicator light should be illuminated If the reverse light does not illuminate when shifted to the reverse position the switch may be faulty the fuse may be blown the bulb may be faulty a connection may be loose or corroded or the lever may need adjusting To adjust proceed to Adjusting Shift Lever ADJUSTING SHIFT LEVER 1 Remove the seat then r...

Page 17: ...eral times to check for a firm brake If the brake is not firm the system must be bled 3 To bleed the main brake system use the following procedure A Remove the cover and fill the reservoir with DOT 4 Brake Fluid B Install and secure the cover then slowly compress the brake lever several times C Remove the protective cap install one end of a clear hose onto one FRONT bleeder screw and direct the ot...

Page 18: ... HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKING REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear The only maintenance that is required is replacement of the brake pads when they show excessive wear Check the thick ness of each of the brake pads as fol...

Page 19: ...NG 1 Remove the right side footrest see Section 8 2 Remove the cap screws securing the V belt cover noting the location of the different lengthed cap screws for installing purposes then using a rubber mallet gently tap on the cover tabs to loosen the cover Remove the cover CD078 NOTE Note the location of the main engine ground wire for installing purposes 3 Remove the nut securing the movable driv...

Page 20: ...en clutch 4 Place the V belt cover gasket into position then install the cover and secure with the cap screws mak ing sure the different lengthed cap screws are in their proper location Tighten the cap screws to 8 ft lb CD083 NOTE Make sure the main engine ground wire is installed and secured in the proper location 5 Install the right side footrest see Section 8 6 Secure the front fender to the fo...

Page 21: ... ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 Table of Contents 400 TRV 3 6 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 22: ...tem Clearance max intake exhaust 0 04 mm 0 06 mm Valve Guide Valve Stem Deflection max wobble method 0 35 mm Valve Guide Inside Diameter 5 000 5 012 mm Valve Stem Outside Diameter intake exhaust 4 975 4 990 mm 4 955 4 970 mm Valve Stem Runout max 0 05 mm Valve Margin min intake exhaust 0 65 mm 0 75 mm Valve Face Seat Width min intake exhaust 2 12 mm 2 55 mm Valve Seat Angle intake exhaust 45 Valve...

Page 23: ... 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Carburetor jets obstructed 5 Valve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 5 Valve tappets worn ...

Page 24: ...djust clearance 2 Replace service seats valves 3 Replace guides 4 Replace arms shafts 5 Replace magneto 6 Replace CDI unit 7 Adjust gap replace plug 8 Replace ignition coil 9 Adjust float height 10 Clean jets 11 Adjust pilot screw 12 Replace fuel injector Problem Engine runs poorly at high speed Condition Remedy 1 High RPM cut out against RPM limiter 2 Valve springs weak 3 Valve timing out of adju...

Page 25: ... 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 low gasoline poor 4 Oil pump defective 5 Oil circuit obstructed 6 Gasoline level in float chamber too lo...

Page 26: ... the wheels 1 Remove the front rack left and right footwells and front body panel see Section 8 then discon nect the negative battery cable from the battery 2 Remove the heat shield then remove the gas tank see Section 4 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 sp...

Page 27: ...g the exhaust pipe to 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 KC228B For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerp...

Page 28: ...rame 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 components when servici...

Page 29: ...rews 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 6 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken...

Page 30: ...e 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 two alignment pins MD1163 11 Remove the cam chain guide MD1173 C Cylinder D Piston NOTE Steps 1 11 in the prec...

Page 31: ...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 MD1211 A Starting with the top ring slide one end of the ring out of the ring groove B Remove each ring by working it toward the dome of the piston while rotating it out of the groove AT THIS POINT To service cylinder see Servicing Top Side Comp...

Page 32: ...he cover in a fig ure 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 valve springs and remove the valve keepers Account fo...

Page 33: ...he 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 Measuring Valve Guide Valve Stem Deflection Wobble Method 1 Mount a dial indicator and base on the surface plate then place the cylinder head on the surface plate 2 Install the valve into the cylinder head then posi tion the dial indicator contact p...

Page 34: ...e closest wound coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor compress the valve springs and install the valve keepers CC994 PISTON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal tool remove any carbon buildup from the t...

Page 35: ...ceptable ring end gap must be within specifications CC995 Measuring Piston Pin Connecting Rod Small End and Piston Pin Bore 1 Measure the piston pin outside diameter at each end and in the center If measurement exceeds specifications the piston pin must be replaced ATV 1070 2 Inspect and measure the connecting rod small end If the measurement exceeds specifications the connecting rod must be repla...

Page 36: ...inder 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 heli coil insert 3 Place the...

Page 37: ...continuing to move the cylin der in a figure eight motion until a uniform bright metallic finish is attained CC997 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 in three locations from top to bottom a...

Page 38: ...nout maximum tolerance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe height ATV1013A 2 The lobe heights must not exceed minimum speci fications Inspecting 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 repl...

Page 39: ...der pin for damage CF061A NOTE With the weight extended the unloader pin should be flat side out with the weight retracted the unloader pin should be round side out CF060A 2 If damaged the camshaft must be replaced Installing 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 sur...

Page 40: ...e tightened in step 9 KC337A C Cylinder Head Camshaft D Valve 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 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 m...

Page 41: ...nter 11 While holding the cam chain sprocket to the side install the rear 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...

Page 42: ...E Camshaft alignment pin and sprocket alignment hole smallest are aligned 16 Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole MD1363 17 Apply red Loctite 271 to the first cap screw 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 MD1137 18 Rotate the crankshaft until th...

Page 43: ...ure with the two cap screws MD1254 24 Install the cap screw and spring into the end of the cam chain tensioner Tighten securely MD1245 25 Loosen the adjuster screw jam nuts then loosen the adjuster screws on the rocker arms in the valve cover 26 Apply a thin coat of Three Bond Sealant to the mating surface of the cylinder head cover then place the cover into position Note that the two alignment pi...

Page 44: ...he 8 mm cap screw with the washer near the middle of the left side cover Keep the different lengthed 6 mm cap screws in order for installing purposes MD1186 3 Using an appropriate side case puller and the 6 mm adapter remove the left side cover w stator assembly Account for the two alignment pins and the position of the shifter bracket for installing purposes CC946 MD1188 NOTE Inspect the inside o...

Page 45: ...MD1370 7 Remove the starter 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 For Dis...

Page 46: ...Side Components A Starter Idler 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 installed MD1086 4 Install the cam stopper assembly 5 Install...

Page 47: ...nician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A V Belt Cover B Driven Pulley C Clutch Cover 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 cove...

Page 48: ... belt MD1118 6 Remove the 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 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 49: ...Pump Driven Gear NOTE 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 thread...

Page 50: ...en gear 19 Remove oil pump driven gear Account for the drive pin and thrust washer MD1020 H Oil Pump Oil Strainer NOTE Steps 1 19 in the preceding sub sections must precede this procedure 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 F...

Page 51: ... If the housing is damaged in any way the housing must be replaced INSPECTING PRIMARY ONE WAY DRIVE 1 Place the one way clutch onto the clutch 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 wa...

Page 52: ...h red Loctite 271 securely MD1337 2 Place the strainer cap into position on the crank case making sure the O ring is properly installed and secure with the four cap screws then tighten the oil drain plug to 20 ft lb MD1208 3 Place two alignment pins and the oil pump into position on the crankcase and secure with the Phil lips head screws coated with blue Loctite 243 Tighten to 8 ft lb MD1060 4 Pla...

Page 53: ...lutch shoe 8 Install the one way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase MD1286 9 Install gear position switch spacer and switch making sure to align the drive pin with the slot in the shift shaft KC325A KC326B B Clutch Cover C Fixed Drive Face D Movable Drive Face NOTE Steps 1 9 in the preceding sub section must precede this procedure 10 Insta...

Page 54: ...drive face assembly onto the front shaft 15 Spread the faces of the driven pulley by threading a V belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V belt to drop into the pulley approxi mately 3 4 in KC137 NOTE The arrows on the V belt should point in direction of engine rotation 16 Making sure the movable drive face rollers are in posi...

Page 55: ...ighten 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 must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician ...

Page 56: ...ase 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 locating pins and the center bearing locating ring FI660A FI659A FI661A 2 Remove the reverse idler assembly B Account for and note the location o...

Page 57: ...ft fork assembly FI662 6 Remove the crank balancer driven gear G and account for a key then remove the crankshaft bal ancer shaft MD1024 7 Using Crankcase Separator Crankshaft Remover with the appropriate crankshaft protector remove the crankshaft MD1330 CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary If the shaft is removed the shaft nut must be replaced with...

Page 58: ...cklash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove measure and install until backlash measurement is within tolerance Note t...

Page 59: ...ion 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 1 Pus...

Page 60: ...e the reverse driven gear dog then remove the circlip securing the reverse driven gear FI663 FI664 2 Remove the splined washer then remove the reverse driven gear along with the bearing and bushing FI665 CAUTION Care should be taken to support the connecting rod when rotating the crankshaft CAUTION When disassembling the countershaft care must be taken to note the direction each major component do...

Page 61: ...e circlip securing the high driven gear then remove a washer the high driven gear along with the bearing and bushing and remove the high driven washer FI670 FI671 ASSEMBLING 1 With the high driven washer 1 on the counter shaft install the high driven gear bushing 3 bearings 2 and gear 4 on the countershaft then install the washers 5 and secure with the snap ring FI671A For Discount Arctic Cat Part...

Page 62: ...he countershaft then install splined washer 12 FI667A FI666 4 Place the reverse driven bushing 13 onto the shaft then install the bearing 14 gear 15 and splined washer 16 Secure with a snap ring FI665A FI664 5 Install the reverse dog on the shaft then place the shift forks and shift shaft into position FI663 FI662 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com...

Page 63: ...b 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 counterweight is toward the rear of the engine ...

Page 64: ...d install into the crankshaft as an assembly FI662 FI653 8 Align the shift forks to allow engagement with the shift cam then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase FI653A FI655A 9 Install the input driveshaft FI646 10 Install the spacer 1 shaft 2 reverse idler gear and washer 3 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 ww...

Page 65: ...re clean and grease free Apply Three Bond Sealant to the mating surfaces Place the right side half onto the left side half MD1336 2 Using a plastic mallet lightly tap the case halves together until cap screws can be installed 3 From the right side install the crankcase cap screws noting the location of the different sized cap screws then tighten only until snug NOTE Rotate the shafts back and fort...

Page 66: ...lling Engine Transmission 1 From the right side place the engine transmission into the frame tilting the top side forward to clear the frame member KC216 2 Install the front and rear engine mounting through bolts and secure with the flange nuts Tighten to 38 ft lb 3 Align the front and rear output flanges with the drive couplers then secure with the screws with red Loctite 271 and tighten to 20 ft...

Page 67: ...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 KC238 KC170 7 Place the carburetor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe then tighten the clamp securely For Discount Arctic Cat Parts Call ...

Page 68: ...d 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 KC249 KC250 KC251 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www m...

Page 69: ...ection 4 13 Install the front body panel front rack and foot wells see Section 8 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 For Discount...

Page 70: ...ations 4 2 Carburetor 4 2 Electric Choke 4 7 Throttle Cable Free Play 4 7 Engine RPM Idle 4 8 Gas Tank 4 8 Oil Filter Oil Pump 4 8 Testing Oil Pump Pressure 4 9 Oil Cooler 4 9 Vacuum Pulse Fuel Pump 4 9 Troubleshooting 4 10 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 71: ...o the carburetor then remove the cover PR154B 5 Remove the throttle cable from the actuator arm PR162C 6 Loosen the outer jam nut securing the throttle cable to the carburetor body then route the cable out of the way PR162B 7 Disconnect the electric choke lead from the wiring harness 8 Disconnect the vent hose then remove the carbure tor Description p n Oil Pressure Test Kit 0644 495 Seal Removal ...

Page 72: ...ecuring the float chamber then remove the chamber Account for the O ring CC749 CC750 5 Remove the float pin KEY 1 Cover 2 Screw 3 Spring 4 Spring Seat 5 Jet Needle 6 Vacuum Piston 7 Idle Adjust Screw 8 Washer 9 Spring 10 Plate 11 Screw 12 Electric Choke 13 Choke Cover 14 O Ring 15 Float Valve 16 Float set 17 Needle Jet 18 Jet Holder 19 Main Jet 20 Starter Jet 21 Slow Jet 22 Screw 23 Spring 24 Diap...

Page 73: ...oughly 4 Dry all components with compressed air only mak ing sure all holes orifices and channels are unob structed 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 for distortion...

Page 74: ... holder assembly into the carburetor and tighten securely 5 Place the float assembly with float valve into posi tion and secure to the carburetor with the float pin CC753 NOTE Check float arm height by placing the carbu retor on its side w float contacting the needle then measure with a caliper the height when the float arm is in contact with the needle valve Float arm height should be 17 mm 0 7 i...

Page 75: ...3 Place the throttle cable into position and secure by tightening the outer jam nut PR162B 4 Connect the throttle cable to the actuator arm PR162C 5 Place the throttle actuator cover into position on the carburetor then secure with the screw PR154B CAUTION It is important to press down on the pump housing until it contacts the carburetor to make sure the diaphragm lip is properly seated in the gro...

Page 76: ... 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 measure plunger extension Measurement B should be 22 1 23 4 mm KC328C 4 If the choke is damaged or the measurements are not within specifications the choke must be replaced INSTALLING 1 Lightly lubricate the O ring on the choke body then car...

Page 77: ... any way replacement is nec essary 1 Clean all gas tank components with parts cleaning solvent 2 Inspect all hoses for cracks or leaks 3 Inspect tank cap and tank for leaks holes and dam aged threads INSTALLING 1 Place the gas tank into position in the frame then install the cap screws Tighten securely 2 Connect the gas hose from the carburetor then con nect the fuel gauge connector 3 Install the ...

Page 78: ...ler 2 Remove the cap screws securing the oil cooler to the frame Account for grommets 3 Remove the oil cooler from the frame INSTALLING 1 Place the cooler into position in the frame 2 Secure the cooler to the frame with the cap screws and grommets 3 Install the hoses onto their respective fittings and secure with the clamps Vacuum Pulse Fuel Pump The vacuum pulse fuel pump is not a serviceable com...

Page 79: ...emedy 1 Slow jet obstructed loose 2 Slow jet outlet obstructed 3 Low speed fuel screw setting incorrect 4 Float height incorrect 1 Clean tighten jet 2 Clean outlet 3 Adjust screw 4 Adjust float height Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 2 Main jet obstructed 3 Needle jet obstructed 4 Vacuum piston not operating properly 5 Filter obstructed ...

Page 80: ...rature and Cooling Fan Switches 5 5 Fan Motor 5 5 Power Distribution Module PDM 5 6 Ignition Coil 5 6 Speed Sensor 5 7 Ignition Switch 5 8 Handlebar Control Switches 5 8 Drive Select Switch 5 9 Front Drive Differential Lock Actuator 5 10 Stator Coil 5 10 Starter Relay 5 11 Starter Motor 5 11 CDI Unit 5 12 Regulator Rectifier 5 12 Headlights 5 12 Taillight Brakelight 5 13 Ignition Timing 5 13 Troub...

Page 81: ...lean distilled water to bring fluid level to the UPPER level line 6 Using a multimeter test the battery voltage The meter must read 12 5 or more DC Volts for a fully charged battery NOTE At this point if the meter reads as specified the battery may be returned to service see step 10 7 If the meter reads less than specified voltage charge the battery using the following guidelines A When using an a...

Page 82: ...ct the char ger to any DC power outlet RPM Limiter NOTE The ATV is equipped with a CDI unit that retards ignition timing when maximum RPM is approached When the RPM limiter is activated it could be misinterpreted as a high speed misfire Testing Electrical Components All of the electrical tests should be made using the Fluke Model 77 Multimeter and when testing peak voltage the Peak Voltage Reading...

Page 83: ...STANCE Switch Connector 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to one black wire then connect the black tester lead to the other black wire FI502 3 When the brake pedal is depressed the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance replace the switch Brakelight Switch Handlebar Control To access the connector remove the ...

Page 84: ...ld 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 temperature of 140 C 284 F the meter should read an open circuit 5 On the cooling fan switch when the temperature reaches 120 C 248 F the meter should read a closed circuit 6 On the cooling fan switch allow the oil to cool and when the temperature is at or just before a te...

Page 85: ...ht dimmer switch can be in either position NOTE If the meter shows no battery voltage trou bleshoot the battery switches distribution module or the main wiring harness FUSES 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to one spade end of the fuse then connect the black tester lead to the other spade end 3 The meter must show less than 1 ohm resistance If the meter r...

Page 86: ...ct the black tester lead to the black wire 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Speed Sensor NOTE Prior to testing the speed sensor inspect the three wire connector on the speed sensor for con tamination broken pins and or corrosion 1 Set the meter selector to the DC Voltage position 2 With appropriate needle adapters on the meter lead...

Page 87: ...hen connect the other tester lead to pin D 4 The meter must show less than 1 ohm 5 Turn the ignition switch to the LIGHTS position 6 Connect either tester lead to pin A then connect the other tester lead to pin B 7 The meter must show less than 1 ohm 8 Connect either tester lead to pin C then connect the other tester lead to pin D 9 The meter must show less than 1 ohm 10 With the switch in the OFF...

Page 88: ...n circuit 4 With the switch in the RUN position the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance troubleshoot or replace the switch component the connector or the switch wiring harness RESISTANCE Reverse Override The connector is the four prong white one next to the steering post To access the connector the front rack and front fenders must be removed see ...

Page 89: ...st show 0 DC volts 8 Select Differential Lock on the front drive actuator switch then connect the red tester lead to the white orange wire in the supply harness The meter must show 0 DC volts 9 Connect the tester lead to the white green wire in the supply harness The meter must show 0 DC volts NOTE The 4WD and LOCK icons on the LCD should illuminate NOTE If the voltage readings are as specified an...

Page 90: ... lock released and the emergency stop switch in the RUN position 3 Depress the starter button while observing the multimeter The multimeter should drop to 0 volts and a click should be heard from the relay NOTE If a click is heard and more than 1 volt is indicated by the multimeter replace the starter relay If no click is heard and the multimeter continues to indicate battery voltage proceed to st...

Page 91: ...under the rear rack and rear fenders TESTING 1 Start engine and warm up to normal operating temperatures then connect a multimeter to the bat tery 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 voltage should increase with the engine RPM t...

Page 92: ...e NOTE If the meter shows no voltage inspect bulb fuses wiring harness connectors and switches Ignition Timing The ignition timing cannot be adjusted however verify ing ignition timing can aid in troubleshooting other com ponents To verify ignition timing use the following procedure 1 Attach the Timing Light to the spark plug high ten sion lead then remove the timing inspection plug from the left ...

Page 93: ... connections replace battery repair damage Problem Spark plug electrodes overheat or burn Condition Remedy 1 Spark plug incorrect too hot 2 Spark plug loose 3 Mixture too lean 1 Replace plug 2 Tighten plug 3 Adjust carburetor Problem Magneto does not charge Condition Remedy 1 Lead wires connections shorted loose open 2 Magneto coils shorted grounded open 3 Regulator rectifier defective 1 Repair re...

Page 94: ...tuator Differential Lock 6 2 Front Differential 6 3 Drive Axles 6 16 Rear Gear Case 6 19 Hub 6 20 Hydraulic Brake Caliper 6 21 Troubleshooting Drive System 6 24 Troubleshooting Brake System 6 24 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 95: ...TE The actuator will operate only when the igni tion switch is in the ON position The front drive actuator is located on the side of the front drive input housing With the engine stopped and the ignition switch in the ON position a momentary whir ring sound can be heard each time the front drive selec tor switch is shifted or the differential lock is activated If no sound is heard see Section 5 If...

Page 96: ...o tighten this cap screw while the others are loose to ensure proper seating of the actuator 5 Tighten the remaining cap screws then connect the electrical plug to the main harness 6 Turn the ignition switch to the ON position and check the operation by shifting the selector switch several times 7 Secure the wiring harness to the frame with a nylon cable tie then install the inner fender panel Fro...

Page 97: ...uts AF896D 10 Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft then using a rubber mallet tap the end of the axle and free it from the knuckle assembly AF628D 11 Pull the steering knuckle away from the axle KX151 12 Support the axle to not allow it to drop or hang 13 Remove the lower shock bolts Account for the lock nuts then move the shocks aside...

Page 98: ...the inner fender panels 17 Using a T 30 torx wrench remove the three screws securing the front drive actuator to the gear case then remove the actuator AG925 18 Remove the lower differential mounting cap screw Account for a lock nut and washers CD026 19 Remove the upper differential mounting cap screws CAUTION Do not attempt to use a slide hammer or differential axle damage will occur For Discount...

Page 99: ...o model The technician should use dis cretion and sound judgment 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing GC004A 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for assem bling purposes GC015 CD106 3 Using a boot clamp pliers or suitable substitute remove the boot clamps th...

Page 100: ... 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 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymower...

Page 101: ...t clamp and the rear boot with an appropriate boot clamp CD112 CD099 5 Place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to 23 ft lb NOTE If a new gear case housing is being installed tighten the cap screws to 25 31 ft lb CD103 Disassembling Differential Assembly NOTE This procedure can be performed on a rear gear case 1 Using a T ...

Page 102: ...pring of the differential lock assembly and set aside Note position of parts for assembling purposes KX175 5 Remove the left differential bearing flange assembly and account for a shim Mark the shim as left side KX177 KX178 6 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s and mark as right side KX179 KX181 For Discount Arctic Cat Par...

Page 103: ...ammer remove the pinion gear from the gear case housing CC878 3 Secure the pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar and a bearing CC879 4 Remove any reusable parts from the gear case hous ing then discard the housing and lock collar Assembling Pinion Gear 1 Install the bearing onto the pinion shaft Install the pinion shaft collar CC882 CC883...

Page 104: ...ming Procedure Shim Selection It is very important to adjust bevel gears for the proper running tolerances Gear life and gear noise are greatly affected by these tolerances therefore it is very impor tant to properly adjust any gear set prior to final assem bly The following procedure can be used on both front differ ential or rear drive gear case NOTE All bearings must be installed in the gear ca...

Page 105: ...cover then make sure the bear ing flange is completely seated in the cover GC032A GC033A 4 Install the existing shim or a 0 063 in shim on the cover side of the ring gear then place the assembled gear case cover onto the gear case and secure with three cap screws Tighten evenly using a crisscross pattern GC036B 5 Place the Backlash Gauge Tool into the splines of the ring gear and install a dial in...

Page 106: ...l indicator contacting the ring gear axle flange GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008 in 3 To increase end play decrease the shim thickness To decrease end play increase the shim thickness NOTE Once proper backlash and end play are established the gear case can be assembled see Assembling Differential Assembly ...

Page 107: ... the cover with existing cap screws coated with green Loctite 609 Account for the ID tag Tighten the cap screws evenly to 23 ft lb NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new housing is being installed tighten the cap screws to 28 ft lb 6 Install the shift fork shaft w spring into the housing making sure the shaft O ring is positioned to the inside CC892 7 Install...

Page 108: ...DIFFERENTIAL 1 Align the splined input yoke with the front output splines then place the differential into position on the frame and install the cap screws washers and flex lock nuts Tighten to 38 ft lb Make sure the rubber boot is properly seated on the input yoke CD857 CD859 2 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 ...

Page 109: ...l and spread the cotter pins AF896D AF895D 9 Install the brake calipers and secure with new patch lock cap screws tightened to 20 ft lb AF894D 10 Install the wheels and tighten to 40 ft lb 11 Remove the ATV from the support stand Drive Axles REMOVING REAR DRIVE AXLE 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock WARNING Make sure...

Page 110: ...DRIVE AXLE NOTE For removing a front drive axle see Front Differential in this section CLEANING AND INSPECTING NOTE Always clean and inspect the drive axle com ponents to determine if any service or replacement is necessary 1 Using a clean towel wipe away any oil or grease from the axle components CD019 2 Inspect boots for any tears cracks or deterioration NOTE If a boot is damaged in any way it m...

Page 111: ...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 nut Tighten to 50 ft lb 3 Secure the tie rod to the steering knuckle with a n...

Page 112: ...cessive wear missing or chipped teeth or discoloration 2 Inspect the thrust button for excessive wear or dis coloration 3 Inspect the bearings for discoloration roughness or excessive wear NOTE For servicing bearings or seals see Front Differential in this section Installing Shimming NOTE Ring gear clearance must be adjusted prior to selecting shim for the thrust button 1 Install the thrust button...

Page 113: ...cap screws securing the brake disc CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Clean all hub components 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...

Page 114: ...vice 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 blow the piston free of the housing...

Page 115: ...nce of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing seals and brake piston PR715 PR717A 2 Press the piston into the caliper housing using hand pressure only Completely seat the piston then wipe off any excessive brake fl...

Page 116: ... and install it on the caliper Tighten to 20 ft lb 8 Fill the reservoir then bleed the brake system see Section 2 9 Install the wheel Tighten to 40 ft lb 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 solvent or replaced with new pads Failure to do so will result in r...

Page 117: ... 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 leaks 5 Replace master cylinder Problem B...

Page 118: ...SPENSION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 3 Rear A Arms 7 5 Wheels and Tires 7 6 Troubleshooting 7 8 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 119: ...ring AF730D CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Clean all shock absorber components using a pres sure washer 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock rods sleeves bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Plac...

Page 120: ...nuckle AF618D 7 Remove the cap screws securing the ball joints to the knuckle AF628D 8 Tap the ball joints out of the knuckle then remove the knuckle 9 Remove the lower shock absorber eyelet from the upper A arm 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remove the circlip from the ball joint then remove the ball joint from the A arm WARNING Make sure the ATV is solidly su...

Page 121: ...s into the frame mounts and secure with the cap screws Only finger tighten at this time AF610D 3 Route the brake hose through the upper A arm shock absorber mount then secure the hose to the A arm with a cable tie and grommet DE054A 4 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut to 50 ft lb 5 Secure the A arm assemblies to the frame mounts from step 2 Tighten the ca...

Page 122: ...ort stand Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut Release the brake lever lock 5 Remove the caliper right side only NOTE Do not allow the brake calipers to hang from their cable hose 6 Remove the cap screws and lock...

Page 123: ...the brake hose is properly routed and secured to the upper A arm DE054A 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 NOTE If the cotter pin does not line up always tighten to the next alignment 9 Secure the shock absorber to the frame with a ...

Page 124: ...t indicate forward direction of rotation AF612D CHECKING INFLATING 1 Using an air pressure gauge measure the air pressure in each tire Adjust the air pressure as necessary to meet the recommended inflation pressure 2 Inspect the tires for damage wear or punctures NOTE Be sure all tires are the specified size and have identical tread pattern NOTE If pulling is noted measure the circumfer ence of th...

Page 125: ... Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Auxiliary brake adjusted incorrectly 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 1 Replace bearings 2 Replace tires 3 Replace rim 4 Tighten cap screws 5 Adjust brake 6 Replace bushing 7 Replace shock absorber 8 Tighten nut...

Page 126: ...ng Knuckles 6 Measuring Adjusting Toe Out 7 Front Rack 9 Front Bumper Assembly 9 Front Body Panel Side Panels 9 Footrests 13 Belly Panel 13 Exhaust System 13 Rear Body Panel Rack 13 Taillight Assembly 14 Seat 15 Troubleshooting 16 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 127: ...ical torque specifications are located in Section 1 Steering Post Tie Rods REMOVING 1 Remove the ignition switch retaining ring then remove the reinstallable rivets securing the instru ment pod to the mounting bracket and remove the pod and LCD gauge FI463A FI464A 2 Remove the reinstallable rivets securing the radiator access cover and remove the cover FI465A 3 Remove four reinstallable rivets sec...

Page 128: ...two housings CD760 8 Using a suitable lift stand raise the ATV enough to remove the front wheels CD685 9 Remove the cotter pins and slotted nuts from the inner and outer tie rod ends then remove the tie rods from the steering post arm and the left side and right side steering knuckles AF778D KX039 10 Remove two cap screws securing the lower steering post bearing flange to the frame then remove the...

Page 129: ...ering post and secure the housings to the frame with two cap screws Tighten to 20 ft lb CD760 3 Install the tie rods and secure with the slotted nuts Tighten to 30 ft lb then install new cotter pins NOTE If the slots do not align with the holes in the tie rod ends tighten the nuts just enough to allow installation of the cotter pins AF778D 4 Install the front wheels and tighten to 40 ft lb using a...

Page 130: ...ked or damaged in any way replacement is nec essary 1 Inspect the grip for wear cuts or cracks 2 Inspect the grip for deterioration 3 If a grip is damaged cut the grip lengthwise using a sharp knife or box cutter the 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 ...

Page 131: ...ged in any way replacement is nec essary 1 Clean all knuckle components 2 Inspect the bearing for pits gouges rusting or pre mature wear 3 Inspect the knuckle for cracks breaks or porosity 4 Inspect threads for stripping or damage ASSEMBLING AND INSTALLING 1 Install the bearing then install the snap ring making sure it seats into the knuckle PR287A 2 Install the knuckle to the upper and lower ball...

Page 132: ...om the support stand Measuring Adjusting Toe Out 1 Thoroughly wash the ATV to remove excess weight mud etc 2 Refer to the specifications and ensure the tires are properly inflated to the recommended pressure NOTE Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur 3 Place the ATV in a level position taking care not to push down or lift up on the front end the...

Page 133: ...s should be equal If the measurements are equal proceed to step 8 if the measurements are not equal proceed to step 7 7 To make the measurements equal loosen the appro priate tie rod jam nuts and adjust accordingly then proceed to step 8 AF617D AF778D NOTE The front wheels do not have to be removed to adjust the tie rod Also care should be taken not to disturb the handlebar position 8 Using a perm...

Page 134: ...sses for stripping 4 Inspect for missing decals and or reflectors INSTALLING 1 Place the rack into position on the frame and front fender panel Install the cap screws and lock nuts and finger tighten only 2 Install the two cap screws and lock nuts securing the rack to the fenders Tighten all hardware securely Front Bumper Assembly REMOVING 1 Remove the two flange bolts and lock nuts securing the u...

Page 135: ...einstallable rivets securing the instrument pod then remove the instrument pod FI463A FI464A 5 Remove the cap screws and lock nuts securing the front rack to the frame then remove the front rack Account for the grommets and bushings FI469A 6 Remove the side panels by pulling on them to release the tabs from the body then remove the screws securing the rear of the front panel to the frame For Disco...

Page 136: ...ift the rear up to clear the handlebar CD765A NOTE It may be necessary to rotate the body panel to the right to align the opening with the handlebar CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Clean all fender components with warm soap and water 2 Inspect fenders for cracks and or loose rivets 3 Inspect for any missing ...

Page 137: ... spring shift lever and pivot axle then tighten the axle nut securely CD779 7 Install the instrument pod and ignition switch then secure with two reinstallable rivets and the ignition switch retaining ring 8 Set the storage compartment box into position then install the storage compartment cover making sure the mounting tabs engage the slots Slide rearward to secure and lock by engaging the lid lo...

Page 138: ...he machine screws and shoulder washers securing the belly panel to the underside of the frame then remove the belly panel 2 Place the belly panel into position on the underside of the frame then install the machine screws and shoulder washers Tighten securely Exhaust System REMOVING MUFFLER 1 Remove the two exhaust springs at the muf fler exhaust pipe juncture CF138A 2 Slide the muffler rearward t...

Page 139: ...aded areas of all mounting bosses for stripping 4 Inspect for missing decals INSTALLING 1 Remove the gas tank cap and set the rear body panel in position then install the cap and connect the tail light brakelight connector 2 Place the rear rack in position with the bushings and secure with the cap screws and lock nuts Tighten securely 3 Install one shoulder screw and three plastic rivets on each s...

Page 140: ...he rear and rotate them to the vertical position CF226 2 Lift the rear of the seat up then pull slightly to the rear and lift the seat off the mountings CF227A 3 To lock the seat into position engage the two front mounting lugs into the mounting rack then holding down firmly on the front of the seat push the seat forward until the rear tabs engage the rear mounting latches CF229A 4 Lock the seat i...

Page 141: ...ing 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 Problem Tire...

Page 142: ...ONTROLS INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 3 Shift Lever 9 4 LCD Gauge 9 4 For Discount Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 143: ...der housing by gently pressing it toward the pivot pin hole in the housing then lay it aside leaving the switch and wiring harness connected BC205 5 Remove the clamp screws securing the brake housing to the handlebar then remove the assem bly from the handlebar DE058A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the pin securi...

Page 144: ...lever pivot pin and snap ring BC206 4 Bleed the brake system see Section 2 Throttle Control REMOVING 1 Remove the two machine screws securing the throttle control to the handlebar 2 Slide the grommet out of the lower half of the throttle control then remove the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm to the throttle control lever A...

Page 145: ...ng and two O rings INSTALLING 1 Place the spring into position between the upper shift arm and shift lever then making sure the O rings are in place on the axle secure the shift lever to the arm with the existing axle and nut 2 Place the shift rod into position on the shift lever and secure with the existing E clip 3 Check shift lever adjustment see Section 2 then tighten jam nut s securely 4 Inst...

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