Arctic Cat 450 2010 Page 8 Service Manual Download | Manualshive

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SECTION 2 -

PERIODIC MAINTENANCE

TABLE OF

CONTENTS

Periodic Maintenance Chart .................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter ................................................................... 2-3
Valve/Tappet Clearance

(Feeler Gauge Procedure) ................................... 2-4

Valve/Tappet Clearance

(Valve Adjuster Procedure) .................................. 2-4

Testing Engine Compression .................................. 2-5
Spark Plug............................................................... 2-6
Muffler/Spark Arrester ............................................. 2-6
Engine/Transmission Oil - Filter - Strainer .............. 2-6
Front Differential/Rear Drive Lubricant .................... 2-8
Driveshaft/Coupling ................................................. 2-9
Nuts/Bolts/Cap Screws............................................ 2-9
Headlights/Taillight-Brakelight ................................. 2-9
Shift Lever ............................................................. 2-10
Frame/Welds/Racks .............................................. 2-10
Hydraulic Brake Systems ...................................... 2-11
Burnishing Brake Pads.......................................... 2-13
Checking/Replacing V-Belt ................................... 2-13

Manual

Table of Contents

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

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Summary of Contents for 450 2010

Page 1: ...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 practi...

Page 2: ...General 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...

Page 3: ...ns 1 2 Torque Conversions ft lb N m 1 3 Tightening Torque General Bolts 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...

Page 4: ...uckle A Arm 50 68 SUSPENSION COMPONENTS Rear Shock Absorber Upper Frame 50 68 Shock Absorber Lower Lower A Arm 20 27 A Arm Frame 50 68 Knuckle A Arm 50 68 DRIVE TRAIN COMPONENTS Engine Mounting Throug...

Page 5: ...he recommended gasoline to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methan...

Page 6: ...dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV to dry thoroughly DO NOT get water into any part of the engine or air intake 3 Eith...

Page 7: ...ecessary 4 Change the engine transmission oil and filter 5 Check the coolant level and add properly mixed coolant as necessary 6 Charge the battery then install Connect the bat tery cables 7 Check the...

Page 8: ...pression 2 5 Spark Plug 2 6 Muffler Spark Arrester 2 6 Engine Transmission Oil Filter Strainer 2 6 Front Differential Rear Drive Lubricant 2 8 Driveshaft Coupling 2 9 Nuts Bolts Cap Screws 2 9 Headlig...

Page 9: ...rrester C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R 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...

Page 10: ...ing procedure to remove the filter and inspect and or clean it CLEANING AND INSPECTING FILTER 1 Remove the seat then remove the cap screws securing the storage compartment 2 Raise the storage compartm...

Page 11: ...ons Tighten each jam nut securely after completing the adjustment CC007DC 4 Install the timing inspection plug then install the crankcase end cap 5 Place the two tappet covers into position making sur...

Page 12: ...the timing inspection plug Testing Engine Compression To test engine compression use the following proce dure 1 Remove the high tension lead from the spark plug 2 Using compressed air blow any debris...

Page 13: ...spark arrester assembly to the muffler then loosen and remove the arrester CF105A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the s...

Page 14: ...wait approximately one minute 10 Remove the oil level stick and wipe it with a clean cloth 11 Install the oil level stick and thread into the engine case 12 Remove the oil level stick the oil level mu...

Page 15: ...ove each fill plug AL677C 3 Drain the lubricant into a drain pan by removing in turn the drain plug from each ATV0082A 737 651B 4 After all the lubricant has been drained install the drain plugs and t...

Page 16: ...headlight housing then discon nect from the wiring harness 2 Connect the new bulb assembly to the wiring har ness connector then insert into the headlight hous ing and rotate fully clockwise TAILLIGHT...

Page 17: ...ing To adjust proceed to Adjusting Shift Lever ADJUSTING SHIFT LEVER 1 Remove the seat then remove the left side engine cover 2 With the ignition switch in the ON position loosen jam nut A left hand t...

Page 18: ...r screw and direct the other end into a container then while holding slight pressure on the brake lever open the bleeder screw and watch for air bubbles Close the bleeder screw before releasing the br...

Page 19: ...ced 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...

Page 20: ...t 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 ta...

Page 21: ...to position then install the cover and secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighten the cap screws to 8 ft lb CD083 NOTE Make sure the...

Page 22: ...MISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 450 Table of Contents 3 6 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 5...

Page 23: ...Clearance max intake exhaust 0 1 mm 0 3 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 10 mm Valve Margi...

Page 24: ...n 4 Replace fuel pump Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 ECU defective 4 Fuel injector obstructed 5 Valve clearance out of adjustment 1 Clean plug...

Page 25: ...ve 6 ECU defective 7 Spark plug fouled gap too wide 8 Ignition coil defective 9 Fuel injector obstructed 1 Adjust clearance 2 Replace service seats valves 3 Replace guides 4 Replace arms shafts 5 Repl...

Page 26: ...1 Drain excess oil change oil 12 Tighten replace manifold 13 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 2 Oil low 3 Octane low gasoline poor 4...

Page 27: ...ve 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 senso...

Page 28: ...er 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 re...

Page 29: ...ion 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...

Page 30: ...oses 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 secu...

Page 31: ...ket 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...

Page 32: ...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...

Page 33: ...e 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 Mea...

Page 34: ...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...

Page 35: ...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 Inspecti...

Page 36: ...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 Inst...

Page 37: ...imum distortion must not exceed specifica tions CC141D Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting scoring scuffing warpage and corros...

Page 38: ...using soap and hot water Dry with compressed air then immedi ately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder CC390D 4 If any measurement exceeds th...

Page 39: ...nder 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...

Page 40: ...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 cran...

Page 41: ...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...

Page 42: ...ocket 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...

Page 43: ...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 27 to 8 ft lb 27 Adjust valve tappet clearance see Se...

Page 44: ...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...

Page 45: ...Shaft H Drive Gear NOTE Steps 1 10 in the preceding sub section 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...

Page 46: ...ions 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...

Page 47: ...r 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...

Page 48: ...ace 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...

Page 49: ...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 using red Loctite...

Page 50: ...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 f...

Page 51: ...te 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...

Page 52: ...move 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 CAU...

Page 53: ...ever 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 dis...

Page 54: ...h 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...

Page 55: ...ys 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 posi...

Page 56: ...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...

Page 57: ...til 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...

Page 58: ...s 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 assem...

Page 59: ...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...

Page 60: ...4 While rocking the driven bevel 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 meas...

Page 61: ...of specification the assembly 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...

Page 62: ...ing 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 wi...

Page 63: ...move 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 d...

Page 64: ...and secure with snap ring 7 then install the 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...

Page 65: ...ankcase half NOTE If the output shaft was removed make sure that the proper shim is installed 1 Install the output shaft into the crankcase making sure the two gears shim washer and nut are in the cor...

Page 66: ...n install the gear and aligning the timing marks slide the gear into place FI658 6 Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end install in the c...

Page 67: ...the recesses 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 c...

Page 68: ...ng 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...

Page 69: ...e 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...

Page 70: ...Fuel Injector 4 4 Throttle Cable Free Play 4 4 Engine RPM Idle 4 5 Gas Tank 4 5 Oil Filter Oil Pump 4 5 Testing Oil Pump Pressure 4 5 Liquid Cooling System 4 6 Electric Fuel Pump Fuel Level Sensor 4 8...

Page 71: ...ing by listen ing for a momentary whirring sound when the ignition switch is turned to the ON position If no sound is heard refer to Power Distribution Mod ule PDM in Section 5 or Electric Fuel Pump F...

Page 72: ...LING 1 Install the throttle body into the intake boot and secure with the clamp Tighten securely 2 Connect the throttle cable to the throttle body and adjust throttle free play see Section 2 3 Connect...

Page 73: ...hen connect the gasline hose 8 Install the air filter housing assembly see Throttle Body INSTALLING steps 4 7 in this section 9 Connect the negative battery cable to the battery Throttle Cable Free Pl...

Page 74: ...cap screws Tighten securely 3 Connect the gasline hose connector to the fuel pump outlet then connect the fuel pump fuel level sensor connector 4 Install the vent hose then fill the gas tank with gas...

Page 75: ...der panel see Section 8 4 Remove the upper and lower coolant hoses 5 Remove the cap screws and nuts securing the radi ator to the frame 6 Disconnect the fan wiring from the main wiring harness then re...

Page 76: ...deterioration cracks and wear NOTE All coolant hoses and clamps should be replaced every four years or 4000 miles Installing Place the thermostat and O ring into the thermostat housing then secure the...

Page 77: ...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 indica...

Page 78: ...new fuel pump with a reference mark in the same location as the removed pump then place the new gasket on the pump 2 Remove the material covering the fuel pump open ing then carefully guide the fuel...

Page 79: ...g 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 Back Se...

Page 80: ...5 6 EFI Sensors Components 5 7 Speed Sensor 5 8 Ignition Switch 5 8 Handlebar Control Switches 5 9 Drive Select Switch 5 10 Front Drive Differential Lock Actuator Power 5 10 Stator Coil Crankshaft Pos...

Page 81: ...uid level to the UPPER level line lead acid battery NOTE This ATV may be equipped with a sealed battery Do not attempt to add electrolyte to these batteries 6 Using a multimeter test the battery volta...

Page 82: ...e battery cover then connect the charger leads positive cable first directly to the battery B Locate the rear accessory connector and con nect the charger leads positive cable first directly to the co...

Page 83: ...ter shows no battery voltage troubleshoot the battery fuse switch or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good proceed to test the switch componen...

Page 84: ...d be allowed to touch the bottom of the con tainer or inaccurate readings will occur Use wire holders to suspend the sensor and thermometer 3 On the ECT sensor when the temperature reaches 60 C 140 F...

Page 85: ...o battery voltage troubleshoot the battery switches distribution module or the main wiring harness FUSES NOTE To remove a fuse compress the locking tabs on either side of the fuse case and lift out 24...

Page 86: ...wire and the black tester lead to the blue white wire 3 Turn the ignition switch to the ON position The meter must show battery voltage EFI Sensors Components CRANKSHAFT POSITION CKP SENSOR To test th...

Page 87: ...he speed sensor harness or from the speed sensor then remove the Allen head cap screw securing the sensor to the sensor housing 2 Remove the sensor from the sensor housing accounting for an O ring 3 I...

Page 88: ...ss than 1 ohm NOTE If the meter shows more than 1 ohm of resistance troubleshoot or replace the switch component the connector or the switch wiring harness RESISTANCE LO Beam 1 Connect the red tester...

Page 89: ...he battery must be connected when per forming voltage tests 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire 3 Connect the red tester lead to the o...

Page 90: ...ator coil tests failed check all connections etc and test again If no voltage is present replace the stator assembly RESISTANCE AC Generator 1 Set the meter selector to OHMS position 2 Test between th...

Page 91: ...t If the following test does not result as speci fied the starter must be replaced TESTING VOLTAGE Perform this test on the starter motor positive terminal To access the terminal slide the boot away N...

Page 92: ...coil voltage is normal replace the regula tor rectifier Headlights The connectors are the four 2 prong ones plugged into the headlight bulbs two on each side VOLTAGE NOTE Perform this test in turn on...

Page 93: ...ible Short to Battery Low Signal Level too Low Possible Short to Ground or Short to Chassis SG Possible Short to Ground or Short to Chassis Open Open Circuit Possible Broken Wire or No Connection 1 Th...

Page 94: ...wire plug to the sensor then remove the right side mounting screw securing the sensor to the rear frame CD707 2 Install the needle adapters to the multimeter leads then select DC Voltage on the multi...

Page 95: ...ires in the wiring harness 4 Turn 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 ope...

Page 96: ...ce 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...

Page 97: ...elow the specification Condition Remedy 1 Lead wires shorted open loose at terminals 2 Stator coils magneto grounded open 3 Regulator rectifier defective 4 Electrolyte low 5 Cell plates battery defect...

Page 98: ...emedy 1 Electrolyte contaminated 2 Specific gravity too low 3 Charging system not charging 4 Cell plates overcharged damaged 5 Battery short circuited 6 Specific gravity too low 1 Replace battery 2 Ch...

Page 99: ...ferential Lock 6 2 Front Differential 6 3 Drive Axles 6 16 Rear Gear Case 6 21 Hub 6 21 Hydraulic Brake Caliper 6 22 Troubleshooting Drive System 6 26 Troubleshooting Brake System 6 26 Manual Table of...

Page 100: ...NOTE The actuator is not a serviceable compo nent If it is defective it must be replaced NOTE The actuator will operate only when the ignition switch is in the ON position The front drive actuator is...

Page 101: ...emaining cap screws AG928 4 Loosen the front cap screw then tighten the cap screw on the driveshaft side AG926 NOTE It is important to tighten this cap screw while the others are loose to ensure prope...

Page 102: ...alipers for this procedure 7 Remove the two brake calipers Account for the four cap screws AF894D 8 Remove the tie rod cotter pins and discard the pins AF895D 9 Remove the tie rod lock nuts AF896D 10...

Page 103: ...anels 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...

Page 104: ...on and sound judgment 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing CD102 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spri...

Page 105: ...AF994 2 Install the input shaft seal making sure it is flush with the edge of the housing 3 Lubricate the input shaft with High Performance 2 Molybdenum Disulphide Grease packing the boot ribs and spl...

Page 106: ...g installed tighten the cap screws to 25 31 ft lb CD103 Disassembling Pinion Gear NOTE This procedure can be performed on a rear gear case 1 Using a T 40 torx wrench remove the cap screws securing the...

Page 107: ...nge 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...

Page 108: ...ear case housing is being replaced proceed to the following Shimming Proce dure Shim Selection sub section Shimming Procedure Shim Selection 1 Press bearings into bores by outer ring to contact with s...

Page 109: ...CC882 CC883 2 Place the pinion assembly in a bearing puller then install the bearing using a press CC884 3 Install the pinion gear assembly into the housing Using the 48 mm Internal Hex Socket secure...

Page 110: ...he ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear Install the ring gear in the housing then install the outside shim with the chamfer side of the shi...

Page 111: ...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 gear case 1 Place a...

Page 112: ...e 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 procedu...

Page 113: ...859 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 ft lb 3 Install the front drive actuator with the three torx head cap scre...

Page 114: ...ke calipers to hang from their cable hose 6 Slide the hub out of the knuckle and set aside 7 Remove the cap screw and lock nut securing the knuckle to the upper A arm Discard the lock nut NOTE Never r...

Page 115: ...s for nicks or damage DISASSEMBLING AXLES 1 Using a side cutters or suitable substitute remove the large clamp from the boot CD020 2 Wipe away excess grease to access the retaining ring Using an awl r...

Page 116: ...120 grams of grease The inside joint double offset requires approximately 70 90 grams of grease and the out side bell type requires approximately 35 55 grams When replacing boots use 2 3 of the pack f...

Page 117: ...aces away from the boot CD023 6 Making sure the marks made during disassembling align slide the housing over the bearing ring then completely seat the bearing ring into the housing and install the cir...

Page 118: ...the support stand and release the brake lever lock INSTALLING FRONT DRIVE AXLE 1 Position the drive axle in the gear case and steer ing knuckle then insert the upper A arm ball joint into the steerin...

Page 119: ...e the flange nut securing the hub 4 Remove the brake caliper PR243A 5 Remove the hub assembly 6 Remove the four cap screws securing the brake disc CLEANING AND INSPECTING NOTE Whenever a part is worn...

Page 120: ...ft lb 8 Remove the ATV from the support stand Hydraulic Brake Caliper REMOVING DISASSEMBLING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Drain the brake fluid from...

Page 121: ...d 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 tra...

Page 122: ...e of the housing seals and brake pis ton PR715 PR717A 2 Press the piston into the caliper housing using hand pressure only Completely seat the piston then wipe off any excessive brake fluid PR711A PR7...

Page 123: ...en to 40 ft lb 10 Remove the ATV from the support stand and ver ify brake operation CAUTION If brake pads become contaminated with brake fluid they must be thoroughly cleaned with brake cleaning solve...

Page 124: ...ace 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 s...

Page 125: ...F CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 3 Rear A Arms 7 5 Wheels and Tires 7 7 Troubleshooting 7 8 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR...

Page 126: ...ber spring remove the retainer and remove the spring AF730D CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all shock ab...

Page 127: ...nuckle 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 A...

Page 128: ...the frame mounts and secure with the cap screws Only fin ger 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 ca...

Page 129: ...e the ATV from the support stand Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove th...

Page 130: ...drive axle and into posi tion on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to 50 ft lb 3 Tighten the hardware securing the A arms to the frame mounts f...

Page 131: ...icate forward direc tion of rotation AF612D CHECKING INFLATING 1 Using an air pressure gauge measure the air pres sure in each tire Adjust the air pressure as neces sary to meet the recommended inflat...

Page 132: ...oose 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 Re...

Page 133: ...g Adjusting Toe In 8 6 Front Rack 8 8 Front Bumper Assembly 8 8 Front Body Panel Side Panels 8 8 Footrests 8 10 Belly Panel 8 10 Exhaust System 8 10 Rear Body Panel Rack 8 11 Taillight Assembly 8 12 S...

Page 134: ...s cover and remove the cover 3 Remove two reinstallable rivets securing the steer ing post cover and remove the cover 4 Unlatch the storage compartment lid then slide the storage compartment cover ass...

Page 135: ...t the handlebar tube for cracks wear or unusual bends 8 Inspect the handlebar grips for damage or wear INSTALLING 1 Place the steering post into position then secure the lower bearing flange to the fr...

Page 136: ...cap INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the grip for wear cuts or cracks 2 Inspect the grip for deterioration 3 If a gr...

Page 137: ...or porosity 4 Inspect threads for stripping or damage ASSEMBLING AND INSTALLING 1 Install the bearing then install the snap ring mak ing sure it seats into the knuckle PR287A 2 Install the knuckle to...

Page 138: ...ated 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 lif...

Page 139: ...allel to the belly panel 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 a...

Page 140: ...NSTALLING 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 Ti...

Page 141: ...for cracks and or loose rivets 3 Inspect for any missing decals INSTALLING 1 Rotate the handlebar to the full left position then place the front body panel over the handlebar and rotate and lower into...

Page 142: ...ootrest weldments for cracks or unusual bends 3 Inspect all tubing for cracks or unusual bends INSTALLING 1 Secure the footrests to the frame with four cap screws and two flange nuts then tighten the...

Page 143: ...Front Body Panel Side Panels in this section CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all rear body panel compone...

Page 144: ...Inspect the bulb for wattage voltage and proper operation INSTALLING 1 Place the assembly into position on the frame and secure with torx head cap screws and any washers 2 Tighten the cap screws secu...

Page 145: ...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 wor...

Page 146: ...OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 3 Shift Lever 9 4 Speedometer Tachometer LCD 9 4 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9...

Page 147: ...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 th...

Page 148: ...06 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 thro...

Page 149: ...e 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 shif...

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