Arctic Cat 650 Twin2004 Service Manual Download Page 187

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9-3

INSTALLING

0738-331

1. Position the brake housing on the handlebar.

Secure with clamp screws; then tighten securely.

AG924

2. Install the brake hose on the master cylinder.

Tighten to 0.8 kg-m (6 ft-lb).

AG929

3. Gently press the brakelight switch into the housing

(left to right) until the mounting tabs snap into the

four locating holes; then install the brake lever,

pivot pin, and circlip.

BC206

4. Bleed the brake system (see Section 2).

KEY

1. Brake Assy
2. Screw
3. Cover
4. Screw
5. Clamp
6. Master Cylinder
7. Brake Lever
8. Brake Lever Lock
9. Pin

10. Brake Switch
11. Hose

Summary of Contents for 650 Twin2004

Page 1: ...ATV Service Manual 2004 2004 A A RC C C T T I 650 Twin...

Page 2: ...he words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to fol low the directive because it deals w...

Page 3: ...mation 2 Periodic Maintenance Tune Up 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 10 Aids for Maintenance 11...

Page 4: ...1 SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS General Specifications 1 2 Break In Procedure 1 3 Gasoline Oil Lubricant 1 3 Genuine Parts 1 4 Preparation For Storage 1 5 Preparation After Storage...

Page 5: ...3 6 volts blue to black white 14 0 15 0 volts battery to battery CHASSIS Dry Weight approx 293 kg 646 lb Length overall 205 cm 81 in Height overall 125 cm 49 3 in Width overall 120 7 cm 47 5 in Suspen...

Page 6: ...soline 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 methane or 5 MTBE are a...

Page 7: ...p securely after filling the tank Genuine Parts When replacement of parts is necessary use only gen uine Arctic Cat ATV parts They are precision made to ensure high quality and correct fit Refer to th...

Page 8: ...the battery posts and cables and store in a clean dry area 10 Store the ATV indoors in a level position Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure m...

Page 9: ...1 6 NOTES...

Page 10: ...2 9 Adjusting Throttle Cable 2 9 Adjusting Engine RPM Idle 2 9 Engine Transmission Oil Filter 2 9 Front Differential Rear Drive Lubricant 2 10 Tires 2 11 Steering Components 2 12 Driveshaft Coupling 2...

Page 11: ...sion Oil Level I A Engine Transmission Oil Filter R R R Front Differential Rear Drive Lubricant I R 4 Yrs Tires Air Pressure I I R Steering Components I I I R V Belt I Inspect every 100 hours 1100 mil...

Page 12: ...ChargTim Charge To remove and charge the battery use the following procedure 1 Remove the battery hold down bracket 2 Remove the negative battery cable then remove the positive cable and the battery...

Page 13: ...remove the fuse compress the locking tabs on either side of the fuse cover and lift off KX053A KX202A Air Cleaner Filter The air filter inside the air filter housing must be kept clean to provide goo...

Page 14: ...ng making sure it is properly positioned and properly seated with the filter frame down 9 Install the air filter housing cover and secure with the retaining clips then install the storage com partment...

Page 15: ...each valve tappet clearance If clearance is not within specifications loosen jam nut B and rotate the tappet adjuster screw A until the clearance is within specifica tions Tighten each jam nut to 1 2...

Page 16: ...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 7 While holding the adjuster dial at th...

Page 17: ...ling the spark plug be sure to tighten it to 1 3 kg m 9 5 ft lb A new spark plug should be tight ened 1 2 turn once the washer contacts the cylinder head A used spark plug should be tightened 1 8 1 4...

Page 18: ...securely then slide the rubber boot over the adjuster Adjusting Engine RPM Idle To properly adjust the idle RPM a tachometer is nec essary To adjust idle RPM use the following proce dure 1 With the t...

Page 19: ...gine case NOTE The oil level stick should be threaded into the case for checking the oil level 11 Remove the oil level stick the engine oil level should be above the illustrated L mark but not higher...

Page 20: ...ted with water inspect the drain plug filler plug and or bladder Tires TIRE SIZES The ATV is equipped with low pressure tubeless tires of the size and type listed Do not under any circum stances subst...

Page 21: ...g components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened to specifica tions For proper torque values see Section 10 Ignit...

Page 22: ...iming surface 4 Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights 5 Switch on the lights Make sure the HIGH beam is on DO NOT USE LOW B...

Page 23: ...the left upper body side panel 4 Loosen shift rod end jam nut A AF941A 5 Using two open end wrenches remove lock nut B securing the shift rod to the upper shift axle Discard the lock nut NOTE Never re...

Page 24: ...ator Displays 2WD when the front drive selector switch is moved to the 2WD posi tion Display will go off when 4 WD is selected 8 Coolant Temperature Indicator A red light will illuminate if the engine...

Page 25: ...nd bled at the factory To check and or bleed a hydraulic brake system use the following procedure 1 With the master cylinder in a level position check the fluid level in the reservoir If the level in...

Page 26: ...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 w...

Page 27: ...system use premixed Arctic Cat Antifreeze p n 0638 395 While the cooling sys tem is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engin...

Page 28: ...5 Remove the drive clutch C from the crankshaft using an appropriate clutch puller tool B and turning it clockwise while holding the drive clutch with the drive clutch holder A ATV2059 NOTE Before rem...

Page 29: ...eck the belt deflection A Use a maximum force of 6 kg 13 lb on the ruler Stan dard belt deflection is 22 27 mm 0 87 1 06 in If belt deflection is out of specifications see Section 3 Right Side Compone...

Page 30: ...3 1 3 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Table of Contents 3 3...

Page 31: ...er Inside Diameter 18 mm 22 000 22 026 mm 0 8661 0 8670 in 18 000 18 018 mm 0 8661 0 8670 in Camshaft Journal 22 mm Outside Diameter 18 mm 21 959 21 980 mm 0 8645 0 8654 in 17 966 17 984 mm 0 7073 0 7...

Page 32: ...he wheels 1 Remove the seat then turn the gas tank valve to the OFF position 2 Remove the negative cable from the battery then remove the positive cable Remove the battery hold down strap and the batt...

Page 33: ...10 Remove the neutral position connector F and reverse position connector H then disconnect the forward and reverse detection sensor lead G KX075A 11 Remove the front and rear spark plug caps then rem...

Page 34: ...141 17 Loosen the muffler clamp then remove two mounting bolts securing the muffler to the frame Remove the muffler assembly accounting for one ring gasket and one exhaust pipe bushing seal KX126 18 R...

Page 35: ...OFF position and the tank cap is securely tightened Left Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service...

Page 36: ...alternator and pick up coil lead connectors then remove the alternator cover cap screws A alternator cover B and the two clamps C KX239 7 Remove the ball bearing then thread the flywheel puller A int...

Page 37: ...nnect the drive belt failure detection connector and the engine brake actuator lead then remove the cap screws securing the V belt cover to the crankcase AT THIS POINT To service any one specific comp...

Page 38: ...h an appropriate holder then remove the driven pulley nut and the driven pulley KX246A Top Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which ne...

Page 39: ...installed until the rear rocker case is removed or the cam chain will have to be sup ported while rotating the crankshaft 3 Rotate the crankshaft counterclockwise to position the rear cylinder at TDC...

Page 40: ...guides D KX255 10 Remove the intermediate shaft chain tensioner A then remove the circlip B and washer 11 Remove the intermediate shaft chain guides C then remove the two cap screws D KX251 12 Install...

Page 41: ...drive chain D KX254 15 Remove the front camshaft drive chain from the intermediate sprocket A on the right side then remove the shaft from the engine KX253 16 Remove the cylinder bolts B then remove...

Page 42: ...need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the right crankcase bolts A 6 mm B 8 mm KX258 2...

Page 43: ...shift shaft B KX264 5 Remove the reverse idler shaft A spacer B and reverse drive gear C accounting for a needle bearing and spacer then remove the shifter D and shift rod E KX265 6 Remove the circlip...

Page 44: ...arts including gears shifter gear dogs and splines Replace chipped dam aged or worn parts KX269 9 Check angle A for shift fork bending It must be 90 ATV2069 10 Measure the thickness of the shift fork...

Page 45: ...housing B then tap lightly on the front of the output driven bevel gear shaft C using a plastic mallet The output driven bevel gear and housing come off with the shaft assembly KX274 KX275A NOTE Chec...

Page 46: ...Valve Cover NOTE If the valve cover cannot be trued the cyl inder head assembly must be replaced 1 Wash the valve cover in parts cleaning solvent 2 Place the valve cover on the Surface Plate p n 0644...

Page 47: ...must be within specifications Measuring Valve Face Seat Width 1 Using a micrometer measure the width of the valve face ATV 1004 2 Acceptable width range must be within specifications Measuring Valve F...

Page 48: ...ust be replaced 1 If a valve guide needs replacing insert a valve guide remover into the valve seat side of the valve guide Using a hammer gently drive the valve guide out of the cylinder head CC137D...

Page 49: ...t until within specifications NOTE Repeat procedure on the remaining intake valve CC140D Lapping Valves NOTE Do not grind the valves If a valve is dam aged it must be replaced 1 Remove all carbon from...

Page 50: ...the dome of the piston 2 Inspect the piston for cracks in the piston pin dome and skirt areas 3 Inspect the piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or...

Page 51: ...s the piston pin must be replaced ATV 1070 2 Insert an inside dial indicator into the piston pin bore The diameter must not exceed specifications Take two measurements to ensure accuracy ATV 1069 Meas...

Page 52: ...ith 400 grit wet or dry sandpaper Using light pressure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright...

Page 53: ...of six measurements The trueness out of roundness is the difference between the highest and lowest reading Maximum trueness out of roundness must not exceed specifications CC127D 2 Wash the cylinder i...

Page 54: ...djuster screws and jam nuts CC005D 2 Place a strip of plastigauge in each of the camshaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap sc...

Page 55: ...atic compression release must be replaced 3 Check that the shaft A rotates and the pin B is not broken chipped or worn flat NOTE Do not remove shaft A or pin B as they are not serviceable and cannot b...

Page 56: ...g seats A spring B and thrust plate C KX281 5 Make matching marks A and B on the movable sheave C and stationary sheave D to allow installation in the same position KX282 6 Wipe out excessive grease t...

Page 57: ...movable face then install on the fixed face making sure the alignment marks are properly aligned CD060 4 Install the spring seat C spring D spring seat E and circlip F then attach the spring holder B...

Page 58: ...arts thoroughly in a high flash point solvent ATV2071A Inspecting 1 Inspect the sheave faces A for cracks galling or hollowing then check all bushings B KX288 KX289A KX290A 2 Inspect spider shoes A fo...

Page 59: ...y KX294 2 Place the fixed sheave on the clutch holder then install the movable sheave spider A and shoes B aligning the arrow C with the arrow D on the movable sheave KX295 3 Install the spider wrench...

Page 60: ...h the plastigauge installed ATV2072 4 Measure the crank pin diameter A and check the crankshaft marking B If no mark is on the crankshaft the crank pin diameter should be 39 984 39 992 mm 1 5742 1 574...

Page 61: ...gh the bolt hole B in the drive housing A then rotate the drive bevel gear C until a notch in the internal bearing retainer nut can be seen KX298 2 Install and tighten four nut holding bolts A in the...

Page 62: ...g a special hex wrench B Apply heat to soften the Loctite KX301 7 Remove the outer ball bearing A using a suitable seal and bearing remover B then remove the bevel gear retainer nut and the inner ball...

Page 63: ...ing Crankcase Half NOTE Be sure to clean all parts thoroughly before assembly Use compressed air to ensure that all oil passages are clear of blockage 1 Using a press install ball bearings A and B int...

Page 64: ...s with clean engine oil KX312 5 Apply grease to the lip A of the crankshaft oil seal B then press the seal in so that it sits 3 mm 0 12 in inward C from the end of the housing ATV2081 6 Select connect...

Page 65: ...he crankshaft and inserts then assemble on the crankshaft using clean molybdenum disulfide oil on the inserts A Make sure that the OUT marks B on both connecting rods are directed towards the outside...

Page 66: ...X319A 16 Apply molybdenum disulfide oil to the shift shaft A then install the shift spring C and guide D Apply red Loctite 271 to the shift shaft spring bolt B and tighten to 2 5 kg m 18 ft lb KX320 1...

Page 67: ...kg m 14 5 ft lb following the tightening sequence 1 8 Tighten the 6 mm crankcase cap screws A and B to 1 0 kg m 7 ft lb ATV2084A ATV2085 3 Install the breather tube A on the crankcase fitting alignin...

Page 68: ...the outer ball bearing in until it is bottomed out KX325A 10 Using the bearing driver A drive the bearing into the housing until it bottoms out KX326 11 Place the bearing housing A into the holding f...

Page 69: ...he nuts C until the circlip D can be installed After seating the circlip remove the nuts C compressor B and guide rods A Apply grease to the O ring seal on the housing KX330 KX331A 17 Install the driv...

Page 70: ...housing assembly then clean all oil from the bevel gears Apply a thin even coat of machinist layout dye on the bevel gears 21 Rotate the driveshaft several revolutions in both directions while applyi...

Page 71: ...e set Increase drive housing shims and decrease driven housing shims ATV2091 NOTE Changing driven housing shims will affect backlash more than contact pattern Chang ing drive housing shims will affect...

Page 72: ...338 28 Install the nut A then hold the intermediate shaft from the right side with an Allen wrench and tighten to 4 5 kg m 32 5 ft lb KX339 29 Install the position plate A then tighten cap screws B to...

Page 73: ...side of the crankcase with the tapped hole C directed outward KX345 Installing Right Side Components 1 Install the driven pulley on the transmission driven shaft A being careful not to jam the spline...

Page 74: ...or C then apply clean engine oil to the rotors and shaft D KX350A 2 Make sure that alignment pins A are in place and apply clean engine oil to oil port B KX351 3 Install the oil pump drive chain A wit...

Page 75: ...KX354 8 Install the one way clutch so the flange A fits on the recess B of the race then install on the rotor flywheel and attach with the cap screws Coat threads with blue Loctite 242 and tighten to...

Page 76: ...en the drive clutch cover bolts using a crisscross pattern to 1 3 kg m 9 5 ft lb KX359 Installing Top Side Components A Piston B Cylinder C Cylinder Heads D Camshafts NOTE If the piston rings were rem...

Page 77: ...lls then install the cylinders and clamp A rear only and tighten the cylinder cap screws B to 1 0 kg m 87 in lb Install the cam chain guide C and the oil pipe D KX361 4 Locate alignment pins A as show...

Page 78: ...9 kg m 78 in lb KX364 10 Install pin A spring B washer C and chain tensioner cap bolt D then tighten cap bolt to 2 2 kg m 16 ft lb KX365 11 Apply clean engine oil to the camshaft then apply a thin coa...

Page 79: ...stall the spark plugs if removed and tighten to 1 3 kg m 9 5 ft lb 17 Install the recoil starter assembly B and tighten the cap screws A to 1 2 kg m 9 ft lb KX366 18 Install the V belt cover then tigh...

Page 80: ...a this time KX090 4 Align the engine with the front mount ears and install the front through bolt then install the rear through bolt KX089B KX069A 5 Tighten the rear bracket to frame bolts securely th...

Page 81: ...irt hardware items or liquids then install the carburetors into the intake hoses and tighten the clamps securely Make sure the carburetors are securely seated by rocking side to side after installatio...

Page 82: ...e main harness Connect the spark plug wires 17 Remove the tape from the carburetor inlets checking for any foreign material then using red Loctite 271 install the lower air cleaner housing and tighten...

Page 83: ...3 54 NOTES...

Page 84: ...buretor 4 6 Throttle Cable Free Play 4 8 Engine RPM Idle 4 8 Gas Tank 4 9 Gas Tank Valve 4 9 Gas Vent Hoses 4 10 Electric Fuel Pump 4 10 Oil Flow Chart 4 10 Testing Oil Pump Pressure 4 11 Oil Pressure...

Page 85: ...Bolt 10 Cap 11 O Ring 12 Spring 13 Starter Valve 14 Float Chamber Assy 15 Pump Cover 16 Spring 17 Diaphragm Assy 18 O Ring 19 Float Chamber 20 O Ring 21 Drain Plug 22 Jet Holder 23 Needle Jet 24 Main...

Page 86: ...eck for an air leak between the carburetor and the cylinder head KX025E 8 Check for proper carburetor synchronization by attaching suitable vacuum gauges to the test ports then start the engine and in...

Page 87: ...Loosen the outer jam nut securing the throttle cable to the carburetor body then route the cable out of the way KX137 9 Remove the Phillips head screws holding the cable end plates A then pull out the...

Page 88: ...spring E must not be compressed Float height should be 3 5 mm 0 12 0 20 in ATV2108 NOTE Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level DISASSE...

Page 89: ...l plastic components in a wire basket and submerge in carburetor cleaner 2 Soak for 30 minutes then rinse with fresh parts cleaning solvent 3 Wash all non metallic components with soap and water Rinse...

Page 90: ...C over the needle ATV2110 4 Turn the spring seat A so it does not block the vent hole B ATV2111 5 Install the piston into the carburetor body and engage the tab A of the diaphragm into the recess B t...

Page 91: ...cap screws then install the air filter filter housing cover and storage compartment cover Throttle Cable Free Play 1 Check throttle cable free play at the lever free play should be 3 6 mm 1 8 1 4 in...

Page 92: ...s and rack then install the seat making sure it latches securely Gas Tank Valve The ATV has a valve separate from the gas tank There are two positions ON and OFF KX030 In the OFF position the valve wi...

Page 93: ...hose Make certain that the vent hose is securely connected to the carburetor and the opposite end is always open Electric Fuel Pump The electric fuel pump and fuel level sensor are a non serviceable a...

Page 94: ...ne 2 Remove the oil pressure sender switch then connect the Oil Pressure Gauge p n 0444 039 to the open port using a suitable adapter NOTE Some oil seepage may occur when installing the oil pressure g...

Page 95: ...lly When filling the cooling system use premixed Arctic Cat Antifreeze p n 0638 395 While the cooling sys tem is being filled air pockets may develop therefore run the engine for five minutes after th...

Page 96: ...ants 2 Inspect the radiator for leaks and damage 3 Inspect all hoses for cracks and deterioration 4 Inspect all fasteners and grommets for damage or wear INSTALLING 1 Position the fan fan shroud assem...

Page 97: ...n at 69 5 72 5 C 157 162 F D If the thermostat does not open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear NOTE All coolant hoses and clamps...

Page 98: ...out the mechanical seal A and oil seal B from the inside of the alternator cover using bearing driver C ATV2114 5 Apply high temp grease to the oil seal lip then press oil seal A from the outside of t...

Page 99: ...orrectly inserted then using a new gasket install the water pump cover and tighten the cap screws to 0 9 kg m 78 in lb 11 Install the recoil starter see Installing Left Side Components Section 3 12 In...

Page 100: ...the CDI and the vehicle tilt sensor NOTE To test the fuel gauge tank sensor the fuel pump assembly must be removed REMOVING 1 Remove the rear rack and fenders then disconnect the power supply fuel gau...

Page 101: ...the material covering the fuel pump opening then carefully guide the fuel pump into position taking care not to damage the float or float lever KX190 3 Rotate the fuel pump counterclockwise 90 or unti...

Page 102: ...ock Switch 5 9 Magneto Coils 5 10 Starter Motor 5 11 Starter Relay 5 15 Neutral Start Relay 5 15 CDI Unit 5 16 Regulator Rectifier 5 16 Neutral Start Start in Gear Relays 5 16 Headlights 5 16 Tailligh...

Page 103: ...at the bulb s are good that the connections are clean and tight that the battery is fully charged and that all appropriate switches are activated NOTE For absolute accuracy all tests should be made at...

Page 104: ...age position 2 Connect the red tester to the orange wire then connect the black tester lead to ground AR627D 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troublesho...

Page 105: ...he ignition switch must be in the OFF position 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...

Page 106: ...NOTE If the meter shows no battery voltage troubleshoot the battery fuse motor or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good The connector should b...

Page 107: ...uses are returned to their proper position according to amperage Proper fuse locations are embossed on the power distri bution module Ignition Coils The ignition coils are attached to the upper frame...

Page 108: ...cap Ignition Switch The connector is beneath the front fenders To access the connector the front rack front fenders and instru ment pod must be removed VOLTAGE NOTE Perform this test on the lower sid...

Page 109: ...tch component the con nector or the switch wiring harness RESISTANCE Starter Button 1 Set the meter selector to the Diode position 2 Connect the red tester lead to the orange wire then connect the bla...

Page 110: ...ows other than specified check the harness connector 30 amp fuse and battery connections Front Drive Selector Actuator NOTE With the engine stopped and the ignition switch in the ON position a momenta...

Page 111: ...RPM all wire tests must show 39 59 A C volts NOTE If both charging coil tests failed check all connections etc and test again If no voltage is present replace the stator assembly RESISTANCE Charging C...

Page 112: ...G DISASSEMBLING 1 Disconnect the battery 2 Remove the nut securing the positive cable to the starter then remove the cable from the starter 3 Remove the two cap screws securing the starter to the cran...

Page 113: ...th new brushes and brush springs as a set 5 Inspect the rear cover bushing for wear 6 Inspect the front cover bearing for wear 7 Inspect the brass commutator end of the armature for any burned spots o...

Page 114: ...ed Use a multimeter and the following procedure A Set the selector to the OHMS position B Touch the black tester lead to a ground brush C Touch the red tester lead to the brush holder assembly NOTE If...

Page 115: ...mall amount of grease to the front cover bearing and seal then install the seal protector BC015 BC004 8 Place the front cover onto the starter housing making sure it seats properly 9 Apply red Loctite...

Page 116: ...in the ON position transmission in neutral brake lock released and the emergency stop switch in the RUN position 3 Depress the starter button while observing the multimeter The multimeter should drop...

Page 117: ...heck Voltage Charging Coil No Load in this section If charging coil voltage is normal replace the regulator rectifier Neutral Start Front Drive Actuator Start in Gear Differential Lock Relays The rela...

Page 118: ...iring harness connectors and switches VOLTAGE Brakelight NOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the ON position and the brake either foo...

Page 119: ...negative wire to terminal 16 then connect a jumper wire from terminal 1 to terminal 5 All LCD displays on the speedometer should appear for one second NOTE If any functions segments or displays are no...

Page 120: ...frequency of the oscillator The odometer should start to count faster ATV2125 7 Depress the MODE button A and cycle to trip meters A and B B then check the function of both trip meters in the same man...

Page 121: ...should appear ATV2208E 12 Connect a jumper wire from the negative battery terminal to terminal 8 of the connector The water temperature warning light A should appear ATV2208F ATV2132 13 Connect a jum...

Page 122: ...uld illuminate ATV2208H ATV2136 15 Connect a jumper wire from the positive battery terminal to terminal 12 of the connector The speedometer backing light A should illuminate ATV2208I ATV2138 16 Connec...

Page 123: ...ction 2 for V belt inspection 1 Turn the ignition switch to the OFF position then disconnect the 4 pin connector and the belt indica tor light switch connector KX098A 2 Install the Reset Connector p n...

Page 124: ...gine Brake Actuator Resistance 1 Remove the air duct boot then disconnect the actuator lead connector A KX381 2 Use the multimeter and select the ohms function then measure resistance as follows pins...

Page 125: ...n specifications check the forward reverse detecting sensor If the sensor is normal replace the actuator controller Forward Reverse Detecting Sensor Resistance 1 Disconnect the sensor lead wire connec...

Page 126: ...r lead to the pink white wire terminal 5 and the black tester lead to the black wire terminal 10 in the controller A ATV2147 3 Spin a rear wheel in the forward direction while observing the multimeter...

Page 127: ...ilt sensor to the rear frame KX043 2 Install the needle adapters E to the multimeter leads then select D C Voltage on the multimeter D 3 Connect the red tester lead to the yellow green wire terminal F...

Page 128: ...Wiring Diagram Harness p n 0486 147 739 259A 5 27...

Page 129: ...e System 6 2 General Information 6 2 Rear Suspension Rear Drive Assembly Schematics 6 3 Front Drive Actuator 6 4 Front Differential 6 5 Drive Axles 6 18 Rear Gear Case 6 23 Hub 6 24 Hydraulic Brake Ca...

Page 130: ...tor arm NOTE Small metallic particles will collect on the magnetic drain plug as a normal part of break in and will also give a metallic cast to drained lubri cant Contamination would include large pa...

Page 131: ...Spring 26 Cap Screw 27 Washer 28 Cap Screw 29 Spanner Wrench REAR SUSPENSION AXLE ASSEMBLY KEY 1 Housing 2 Seal 3 Bearing 4 Shim 5 Ring Gear 6 Thrust Button 7 Shim 8 O Ring 9 Cover 10 Filler Plug 11 O...

Page 132: ...0 torx wrench remove the mounting cap screw from the driveshaft side of the actuator AG926 3 Remove the mounting cap screw from below the actuator on the suspension side AG927 4 Loosen but do not remo...

Page 133: ...t Differential NOTE To remove the rear gear case see Rear Gear Case in this section REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the filler plug and the dra...

Page 134: ...Support the axle to not allow it to drop or hang 12 Remove the lower shock bolts Account for the lock nuts then move the shocks aside and secure them with a strap AF897D 13 Remove the upper A arm lock...

Page 135: ...shers CD016 19 Free the differential assembly from the frame mountings then shift the assembly forward in the frame sufficiently to disengage the splines of the driveshaft from the engine KX161 20 Lay...

Page 136: ...tool remove the input shaft seal KX218 6 Remove the snap ring securing the input shaft bearing then place the input shaft housing in a press and remove the bearing KX219 AF984 Assembling Input Shaft...

Page 137: ...screws Tighten to 2 9 3 5 kg m 21 25 ft lb NOTE If a new gear housing is being installed tighten the cap screws to 3 5 4 3 kg m 25 31 ft lb KX209 KX158 Disassembling Pinion Gear NOTE This procedure ca...

Page 138: ...hifter fork pin and spring of the differential lock assembly and set aside Note position of parts for assembling purposes KX175 5 Make match marks on the left bearing housing and differential housing...

Page 139: ...pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar a bearing and a shim CC879 CC880 NOTE If gears are being replaced use the exist ing shims The numbers...

Page 140: ...shim and tighten the bolts to 3 5 4 3 kg m 25 31 ft lb Verify backlash to be within a range of 0 28 0 38 mm 0 011 0 015 in and end play to be within a range of 0 10 0 20 mm 0 004 0 008 in If not with...

Page 141: ...ge of the nut in the oil gallery area then using a hammer stake the nut to ensure that the nut will remain securely tightened CC891 5 Install the shift fork shaft w spring into the gear housing making...

Page 142: ...nstall the outside shim with the chamfer side of the shim toward the ring gear NOTE The spider and ring gear assembly must be replaced as a complete unit CC896 CC897 KX178 9 Install the left bearing h...

Page 143: ...dle 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 Plac...

Page 144: ...5 kg m 125 ft lb CC890 4 Place a punch on the edge of the nut in the oil gallery area then using a hammer stake the nut to ensure that the nut will remain securely tightened CC891 5 Install the input...

Page 145: ...ts Tighten to 6 2 kg m 45 ft lb Make sure the rubber boot is properly seated on the input yoke KX161 AF905D AF904D 2 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid lubricant into the differential and inst...

Page 146: ...4D 10 Install the wheels and tighten to 5 5 kg m 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...

Page 147: ...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 and washer Rele...

Page 148: ...oil leakage then using a slide hammer remove the drive axle AF899D CLEANING AND INSPECTING NOTE Always clean and inspect the drive axle components to determine if any service or replace ment is neces...

Page 149: ...position of the different sized clamps for assembling purposes CD020 8 Apply grease from the kit into the knuckles and the new outer boot NOTE The large grease pack is for the inner drive axle bearing...

Page 150: ...he circlip faces away from the boot CD023 6 Making sure the marks made during disassembling align slide the housing over the bearing ring then install the circlip CD021 7 Slide the boot over the housi...

Page 151: ...RONT 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 tightened to 4 8 kg m 35 ft lb...

Page 152: ...ged with out removing the hub REPLACING WHEEL STUDS 1 Support the ATV on adequate stands or a lift then remove the applicable wheel 2 Thread a lug nut onto the stud then using a hammer drive the stud...

Page 153: ...isc to the hub with the four cap screws coated with blue Loctite 243 Tighten to 2 1 kg m 15 ft lb 2 Apply grease to hub sealing area and on the splines AF736D 3 Install the hub assembly onto the splin...

Page 154: ...2 ASSEMBLING INSTALLING 1 Push the pistons into the caliper as far as they will go to allow clearance for the brake pads 2 Install the brake pads and secure with the pin and cotter pin CD029 3 Place...

Page 155: ...om the support stand and verify brake operation 0739 253 KEY 1 Cap Screw 2 Hose Front 3 Junction Block 4 Plug 5 Cap Screw 6 Caliper 7 Housing 8 Piston Seal Set 9 Seal Set 10 Bleeder Valve 11 O Ring 12...

Page 156: ...6 28 NOTES...

Page 157: ...7 1 7 SECTION 7 SUSPENSION TABLE OF CONTENTS Front and Rear Suspension Assembly Schematics 7 2 Shock Absorbers 7 3 Front A Arms 7 4 Rear A Arms 7 7 Wheels and Tires 7 9...

Page 158: ...22 Seal 23 Cap Screw 24 Drive Axle 25 Clip 26 Boot Repair Kit 27 Cap Screw 28 Cap Screw 29 Boot Guard 30 Body Screw FRONT 31 Spanner Wrench 32 A Arm Brace 33 Cap Screw REAR KEY 1 Knuckle Assy 2 Knuckl...

Page 159: ...r nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock rods dampers bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber sp...

Page 160: ...b assembly 6 Remove the cotter pin and slotted nut securing the tie rod end to the knuckle then remove the tie rod end from the knuckle AF618D 7 Remove the cap screws securing the ball joints to the k...

Page 161: ...signs of damage wear or weldment damage INSTALLING 1 Apply green Loctite 609 to the entire outside diameter of the ball joint then install the ball joint into the A arm and secure with the circlip AF...

Page 162: ...d on the drive axle splines then install the hub assembly onto the drive axle CD009 9 Place the washer onto the shaft then secure the hub assembly with the nut Tighten only until snug 10 Secure the br...

Page 163: ...ng the knuckle to the A arms Discard the lock nuts AF936 NOTE Never reuse a lock nut Once a lock nut has been removed it must be replaced with a new lock nut 10 Remove the cap screws and lock nuts sec...

Page 164: ...cap screws right side only Tighten the hydraulic caliper to 2 8 kg m 20 ft lb NOTE Ensure that the brake hose and brake cable are properly routed and secured to the upper A arm CD007 7 Secure the hub...

Page 165: ...their proper sides CD006 KEY 1 Machine Screw 2 Brake Disc 3 Wheel Hub Front 4 Hub Stud 5 Hub Seal 6 Castle Nut 7 Cotter Pin 8 Wheel 9 Tire Front 10 Mounting Nut 11 Valve Stem 12 Valve Stem Cap 13 Whee...

Page 166: ...ar or punctures NOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Be sure all tires are the specified size and...

Page 167: ...easuring Adjusting Toe In Toe Out 8 8 Body Panel Assembly Schematic 8 10 Front Rack 8 10 Front Bumper Assembly 8 11 Front Fender Side Panels 8 12 Fender Flares Extensions 8 13 Footrests 8 14 Belly Pan...

Page 168: ...ing the side tie rod ends to the knuckles Remove the tie rod ends from the knuckles then remove the tie rods 5 Remove the cap screws securing the steering post bearing flange AL600D 6 Remove the nylon...

Page 169: ...racks wear or unusual bends 8 Inspect the handlebar grips for damage or wear INSTALLING 1 Place the steering post into position then place the upper steering post bearings and housings on the steering...

Page 170: ...s 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 INSTALLING NOTE Before installing a grip use c...

Page 171: ...ckle 9 Remove the seal from the knuckle AF725D 10 Remove the bearing retainer AF726D 11 Remove the bearings CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any w...

Page 172: ...ith the two cap screws Tighten to 4 8 kg m 35 ft lb AF760D KEY 1 Retainer 2 Shock Absorber 3 Bushing 4 Sleeve 5 Adjuster Cam 6 Spring 7 Cap Screw 8 Lock Nut 9 A Arm Assy 10 Bushing 11 Collar 12 Ball J...

Page 173: ...to the splines of the shaft CD009 9 Place the washer onto the shaft then secure the hub assembly with the nut Tighten only until snug CD015 10 Secure the brake caliper to the knuckle with the two cap...

Page 174: ...but with Arctic Cat approved accessories 4 Measure the distance from the outside edge of each handlebar grip to the seat catch brackets CD012A 5 Adjust the handlebar direction until the two measureme...

Page 175: ...ATV forward until the marks are parallel to the belly panel on the back side then measure the overall width of the front tires at the rear side CD013 11 The difference in the measurements must show 6...

Page 176: ...stripping 4 Inspect for missing decals and or reflectors INSTALLING 1 Place the rack into position on the frame and bumper Start the cap screws and finger tighten only 2 Install the two cap screws sec...

Page 177: ...headlights CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all bumper components with parts cleaning solvent 2 Inspect...

Page 178: ...gear shift knob to the shift lever then remove the knob from the lever CC852 4 Remove the three machine screws securing the gear shift linkage cover to the fender and remove the cover NOTE The cover...

Page 179: ...y 4 Connect the drive selector linkage using existing hardware Tighten securely KX057 5 Install the gear shift linkage cover in the left front fender well Tighten securely CC851 6 Place the gear shift...

Page 180: ...rest with existing hardware Tighten securely 4 Tighten the 10 mm footrest cap screws from step 2 to 5 5 kg m 40 ft lb then tighten the 8 mm cap screws from step 2 to 2 8 kg m 20 ft lb 5 Connect the fo...

Page 181: ...Remove the cap screws and washers securing the fender to the frame and footrests 5 Remove the battery hold down and tool kit and disconnect the battery cables negative cable first and the vent hose t...

Page 182: ...the headlights 5 Switch on the lights Make sure the HIGH beam is on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when the most intense beam is centered on the vertical mark 5 c...

Page 183: ...cap screws and any washers 2 Tighten the cap screws securely 3 Route the wiring harness over the rear frame then connect the three prong connector 0739 289 1 To remove the seat pull the seat lock lev...

Page 184: ...8 18 NOTES...

Page 185: ...TROLS INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Auxiliary Brake Assembly Schematic 9 4 Throttle Control 9 4 Drive Selector 9 6 Shift Lever 9 6 Speedometer Electronic I...

Page 186: ...master cylinder 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 b...

Page 187: ...n to 0 8 kg m 6 ft lb AG929 3 Gently press the brakelight switch into the housing left to right until the mounting tabs snap into the four locating holes then install the brake lever pivot pin and cir...

Page 188: ...from the actuator arm KEY 1 Brake Lever 2 O Ring 3 Spring 4 Nut 5 Axle 6 Brake Assy 7 Screw 8 Cover 9 Bladder 10 Master Cylinder 11 Jam Nut 12 Rod Actuator 13 Clevis Pin 14 Washer 15 Cotter Pin 16 Was...

Page 189: ...ING 1 Place the return spring into the throttle control then place the bushing and actuator arm into posi tion Secure with the cap screw lock washer and washer AF679D 2 Using a pair of needle nose pli...

Page 190: ...wheel drive would be the desired choice To either engage or disengage the front wheels move the switch to the 4WD position or to the 2WD posi tion 738 422A Shift Lever The ATV with an automatic trans...

Page 191: ...pring and two O rings on the axle 6 Using two open end wrenches remove the lock nut B securing the shift rod to the upper shift arm Remove the shift rod and discard the lock nut AF941A NOTE Never reus...

Page 192: ...o the 4WD posi tion Display will go off when 2WD is selected 7 2WD Indicator Displays 2WD when the front drive selector switch is moved to the 2WD posi tion Display will go off when 4 WD is selected 8...

Page 193: ...trument pod then remove the ignition switch retaining nut 2 Remove the front rack and front fenders then dis connect the multi pin connector 3 Remove the three nuts securing the mounting studs then re...

Page 194: ...9 10 NOTES...

Page 195: ...10 1 10 SECTION 10 AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications 10 2 Torque Conversions 10 3 Tightening Torque General Bolts 10 3...

Page 196: ...ted To Torque kg m ft lb Brake Disc Hub 2 1 15 Brake Hose Caliper 4 2 30 Brake Hose Master Cylinder 0 8 6 Master Cylinder Cover Master Cylinder 03 10 in lb Auxiliary Brake Lever Footrest 9 7 70 Hydrau...

Page 197: ...9 70 9 7 90 12 5 11 1 5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14 1 9 34 4 7 54 7 5 74 10 2 94 13 0 15 2 1 35 4 8 55 7 6 75 10 4 95 13...

Page 198: ...10 4 NOTES...

Page 199: ...11 1 11 SECTION 11 TROUBLESHOOTING TABLE OF CONTENTS Engine 11 2 Drive 11 6 Fuel System 11 7 Electrical 11 8 Steering Suspension 11 10 Brakes 11 11...

Page 200: ...ce ignition coil 6 Replace high tension lead Problem Engine will not start or is hard to start No fuel reaching the carburetor Condition Remedy 1 Gas tank vent hose obstructed 2 Carburetor inlet needl...

Page 201: ...eems to come from crankshaft Condition Remedy 1 Bearing worn burned 2 Lower rod end bearing worn burned 3 Connecting rod side clearance too large 1 Replace bearing 2 Replace bearing 3 Replace thrust w...

Page 202: ...6 Replace CDI unit 7 Adjust gap replace plug 8 Replace ignition coil 9 Adjust float height 10 Clean jets 11 Adjust pilot screw Problem Engine runs poorly at high speed Condition Remedy 1 High RPM cut...

Page 203: ...st 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 Car...

Page 204: ...Propeller shaft serration worn broken 3 Coupling damaged 4 Coupling joint serration worn damaged 5 Front drive driven bevel gears broken damaged 6 Front differential gears pinions broken damaged 7 Sli...

Page 205: ...ve 5 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 Throttle vacuum piston not operat...

Page 206: ...ark plug electrodes overheat or burn Condition Remedy 1 Spark plug incorrect too hot 2 Engine overheats 3 Spark plug loose 4 Mixture too lean 1 Replace plug 2 Service cooling system 3 Tighten plug 4 A...

Page 207: ...nections Problem Battery sulfation Acidic white powdery substance or spots on surfaces of cell plates Condition Remedy 1 Charging rate too low too high 2 Battery electrolyte excessive insufficient 3 S...

Page 208: ...d 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 w...

Page 209: ...d 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 Problem Braking poor Con...

Page 210: ...ARCTIC CAT Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2257 030...

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