Arctic Cat 700 Diesel 2015 Service Manual Download Page 40

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DE252A

DE285A

DE286A

DE285B

10. Remove the fuel injection control rack by removing

screws (A) and (B) and spring (C); then remove the

governor fork pivot pin. Account for an O-ring.



NOTE: Do not loosen or remove screws (D) or (E) or

fuel delivery equalization will have to be performed.

DE291A

DE327

DE282

11. Remove the governor fork and governor spring

assembly through the opening on the linkage hous-

ing.

DE253

CAUTION

Do not break the seal or turn the torque limiter adjuster
screw. Severe engine damage could occur.

Summary of Contents for 700 Diesel 2015

Page 1: ...S E R V I C E M A N U A L www arcticcat com 700 DIESEL...

Page 2: ...decals display the words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive be...

Page 3: ...ter Components 85 Installing Engine Transmission 98 Troubleshooting 104 Fuel Lubrication Cooling 106 Diesel Fuel Injection System 106 Lift Pump 106 Unit Injectors 107 Injector Timing 107 Fuel Filter 1...

Page 4: ...ree Length min 43 0 mm CYLINDER PISTON AND RINGS Bore x Stroke 75 x 77 6 mm Piston Ring End Gap Installed min 0 25 mm Piston Ring Groove Width 1st 2nd 3rd 0 090 0 125 mm 0 050 0 085 mm 0 040 0 075 mm...

Page 5: ...ng Rod 4 Steps 29 40 Main Bearing Cap Engine Block 6 Steps 44 60 Rocker Arm Support Cylinder Head 29 40 Cylinder Head Cylinder 5 Steps 35 48 Valve Cover Cylinder Head 6 5 9 Driven Pulley Nut Fixed Fac...

Page 6: ...rt of the engine or air intake 3 Fill the fuel tank with fresh 1 or 2 diesel fuel according to ambient temperatures then add a quality anti microbial additive Run the engine in a well ventilated area...

Page 7: ...ter 5 Check the coolant level and add properly mixed coolant as necessary 6 Charge the battery then install Connect the battery cables 7 Check the entire brake systems fluid level pads etc all control...

Page 8: ...the air filter access cover and remove the oper ator s seat then open the clips securing the filter cover and remove the cover from the filter housing DE682A 2 Remove the dry paper air filter Do not...

Page 9: ...lowing procedure 1 Remove the three cap screws securing the spark arrester assembly to the muffler then loosen and remove the arrester CF105A 2 Using a suitable brush clean the carbon deposits from t...

Page 10: ...ilter NOTE Clean up any excess oil after removing the filter 6 Apply oil to a new filter O ring and check to make sure it is positioned correctly then install the new oil filter Tighten until contact...

Page 11: ...plug Make sure not to allow contaminants to enter the opening DE026A 3 Remove the transmission drain plug from the bottom of the transmission and drain the lubricant into a drain pan DE016A 4 Install...

Page 12: ...rear tire inflation pressure should be 0 49 kg cm 7 0 psi Driveshaft Coupling The following drive system components should be inspected periodically to ensure proper operation A Spline lateral moveme...

Page 13: ...Hydraulic Brake Systems CHECKING BLEEDING The hydraulic brake systems have been filled and bled at the factory To check and or bleed a hydraulic brake sys tem use the following procedure 1 With the ma...

Page 14: ...ake 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 e...

Page 15: ...biodegradable glycol based automotive type antifreeze To check add coolant use the following procedure 1 Check the level of coolant in the coolant expansion tank located under the right front fender T...

Page 16: ...ne inch then making sure not to dislocate the one way clutch from the fixed drive hub squeeze the belt together and remove from the drive clutch DE098A INSTALLING 1 Place the V belt into position over...

Page 17: ...ntrols Fuel Filter This diesel powered ATV is equipped with a high effi ciency fuel filter The fuel filter should be changed in accordance with the maintenance schedule or more often if operated under...

Page 18: ...securing the radiator access cover and remove the cover then remove the reinstallable rivets securing the steering post cover and remove the cover CD666 2 Remove the seat 3 Remove the cap screws shou...

Page 19: ...sary to rotate the body panel to the right to align the opening with the handlebar CLEANING AND INSPECTING 1 Clean all fender components with a warm soap and water solution 2 Inspect fenders for crack...

Page 20: ...ts Remove the rear rack Account for the bushings CD690A 2 Remove one shoulder screw and lock nut and three plastic rivets on each side securing the rear body panel to the footwells CD691A 3 Remove two...

Page 21: ...ve the pod NOTE It is not necessary to disconnect any wires from instrument pod components CD759 2 Remove the reinstallable rivets securing the radiator access cover and remove the cover CD666 3 Remov...

Page 22: ...all welded areas for cracks or deterioration 5 Inspect the steering post and steering post brackets for cracks bends or wear 6 Inspect the bearing halves bearing caps and bearing housings for cracks...

Page 23: ...INSPECTING 1 Inspect the grip for wear cuts or cracks 2 Inspect the grip for deterioration INSTALLING NOTE Before installing a grip use contact spray or alcohol to clean the inside of the grip and the...

Page 24: ...and deterioration and the condition of the fittings threaded and com pression 5 Inspect the brakelight switch for corrosion cracks missing or broken mounting tabs or broken and frayed wiring NOTE If t...

Page 25: ...Using a pair of needle nose pliers place the spring into position on the actuator arm AF680D 3 Place the two halves of the throttle control onto the handlebars and secure with the two machine screws A...

Page 26: ...cap from the hub then remove the cotter pin from the nut 3 Remove the nut securing the hub 4 Remove the brake caliper 5 Remove the hub assembly 6 Remove the cotter pin from the tie rod end and remove...

Page 27: ...lb PR264A 8 Pump the hand brake lever then engage the brake lever lock 9 Tighten the hub nut from step 6 to the shaft Tighten to 200 ft lb 10 Install a new cotter pin and spread the pin to secure the...

Page 28: ...the tie rod tighten each jam nut to 35 ft lb Front Rack REMOVING 1 Remove the two shoulder screws and lock nuts securing the front fender panel 2 Remove the cap screws and lock nuts securing the rack...

Page 29: ...rews and two flange nuts then tighten securely 2 Place the footwells onto the footrests then put the foot pegs in position and secure with two cap screws 3 Install the machine screws and flange nuts s...

Page 30: ...to the lights position the headlights and taillight should illuminate Test the brakelight by compressing the brake lever The brakelight should illuminate HEADLIGHT NOTE The bulb portion of the headli...

Page 31: ...step 2 make horizontal marks on the aiming 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...

Page 32: ...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 absorb...

Page 33: ...of this ATV Proper operation during this break in period will help assure maximum life and performance from the ATV Instruct the customer to follow the proper break in procedure as described in the O...

Page 34: ...round to the transmission DE066A DE071A 6 Loosen the two hose clamps securing the air diverter to the inlet hoses then remove the air diverter 7 Remove the upper radiator hose from the filler neck the...

Page 35: ...shers DE078A 12 Remove the fuel supply and fuel return hoses from the fuel rail DE065A 13 Disconnect the wire connectors from the temperature sensor oil pressure sensor gear position switch con nector...

Page 36: ...ecuring the exhaust pipe to the exhaust manifold then remove the exhaust pipe Account for a steel gasket 18 Place a suitable block between the oil pan and frame member then remove the front engine mou...

Page 37: ...NOTE The transmission can be removed for servic ing without removing the engine To remove the transmission use the following procedure 1 Remove the inner front splash shields foot pegs and forward foo...

Page 38: ...iciency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE Th...

Page 39: ...support housing then remove the governor flyweight assembly Account for a small O ring DE245A DE277 8 Remove the control spool thrust bearing and thrust washer Note the order of disassembly and keep t...

Page 40: ...Account for an O ring NOTE Do not loosen or remove screws D or E or fuel delivery equalization will have to be performed DE291A DE327 DE282 11 Remove the governor fork and governor spring assembly th...

Page 41: ...l Assembling Installing 1 Install the governor fork assembly into the cylinder head and secure with the governor fork pivot pin Tighten securely DE282 2 Using a new copper washer install the torque se...

Page 42: ...DE534A 5 Connect the throttle linkage into the throttle control lever then secure with the E clip DE249A 6 Place control spool thrust bearing and thrust washer into the governor flyweight assembly an...

Page 43: ...drive pulley to the camshaft with a washer and cap screw then using an appropri ate holding tool tighten the cap screw to 59 ft lb DE262 10 Install the timing belt see Left Side Components in this sec...

Page 44: ...ift Pump in Fuel Lubrication Cooling DE077B 5 Disconnect the crankcase breather hose from the right front corner of the valve cover DE294A 6 Remove the fuel hoses from the fuel rail then plug or close...

Page 45: ...using rubber bands bind the rocker arms together and lift the assembly off the mounting studs being careful to keep the injector push rods with the injector it was originally installed in DE260C DE529...

Page 46: ...E297A DE299A Inspecting 1 Thoroughly clean the camshaft in parts cleaning sol vent then dry with compressed air 2 Inspect each camshaft journal for scoring heat dis coloring or pitting DE298A 3 Inspec...

Page 47: ...e and record camshaft journal diameter Measurement must not be less than minimum specification DE522 DE523 7 Using a micrometer measure and record camshaft intake exhaust and injection lobe height Mea...

Page 48: ...ncludes a bolt on eccentric to drive the lift pump If the eccen tric has been removed install and tighten the cap screw to 59 ft lb 1 Coat the camshaft journals lobes and camshaft bores in the cylinde...

Page 49: ...all the camshaft drive pulley and cap screw then using a suitable holding tool tighten the cap screw to 59 ft lb DE262 8 Lubricate all rocker shaft components with clean engine oil then install the ro...

Page 50: ...oil return boot Secure with existing hardware DE451 13 Using a crisscross pattern tighten the Allen head cap screws to 6 5 ft lb then tighten the two tamper proof torx head cap screws to 6 5 ft lb 14...

Page 51: ...o prevent fuel leakage DE295A 7 Remove eight standard torx head cap screws from the valve cover then using Torx Head Screwdriver 30 remove the two tamper proof torx head cap screws 8 Remove four Allen...

Page 52: ...injection service facility Installing 1 Thoroughly clean the injector bores in the cylinder head then dry with compressed air DE567A NOTE A small round wire brush can be used to clean injector bores...

Page 53: ...sher so the double ribs are directed toward the injector tip then install the cop per washer on the injector DE569A DE570 NOTE A small amount of lithium grease applied to the washers will aid in keepi...

Page 54: ...the fuel spring DE292 13 Using new O rings install the fuel rail and secure with four Allen head machine screws Tighten to 36 in lb DE534B DE405A 14 Place a small bead of high temperature sealant on t...

Page 55: ...r filter assembly and air diverter Tighten all hose clamps securely 20 Install the front body panel front rack and seat see Steering Frame Controls VALVE CLEARANCE ADJUSTMENT NOTE If the engine has be...

Page 56: ...ster B then tighten the jam nut securely and check clearance C 8 Rotate the crankshaft clockwise 180 and repeat steps 5 7 on the other cylinder 9 Place a small bead of high temperature sealant on the...

Page 57: ...el fuel to the supply fitting using an inlet hose then place a small cup under the bleed hose DE403B 4 Rotate the engine in the direction of rotation clock wise until the 2 flywheel side piston is at...

Page 58: ...nt screw For late timing proceed to step B For early timing proceed to step C DE562A B While watching the bleed hose turn the adjust ment screw clockwise until fuel flow stops DE562B C While watching...

Page 59: ...5 Remove the lift pump and lift pump push rod see Fuel Lubrication Cooling 6 Rotate the crankshaft to approximately 90 after top dead center ATDC DE240A DE275A 7 Turn the camshaft drive pulley until t...

Page 60: ...aid during assembling DE300 DE315 4 Remove the glow plugs 5 Secure the cylinder head using suitable blocks to pre vent damage to the pre combustion chambers then using the Pre Combustion Chamber Ring...

Page 61: ...ge against the head measure any warpage with the feeler gauge Check corner to corner side to side and end to end DE302 NOTE If cylinder head warpage is present the cyl inder head must be planed by a q...

Page 62: ...tic Cat recommends that the compo nents be taken to a qualified machine shop for servicing Assembling Valves 1 Thoroughly clean all valve components in parts cleaning solvent then dry with compressed...

Page 63: ...directed toward the glow plug bore NOTE To simplify installation orientation of the pre combustion chamber install the chamber on the removal tool then place into the head Remove the tool after compl...

Page 64: ...to maintain adequate piston to cylinder head clearance To select the correct cylinder head gasket use the following procedure A Rotate the crankshaft until one of the pistons is at top dead center TD...

Page 65: ...eed 91 mm 6 Apply clean engine oil to the threads of the cylinder head bolts washers the bolt heads and the thrust areas then install and hand tighten 7 Tighten the head bolts to 35 ft lb in 7 ft lb i...

Page 66: ...m the battery 3 Remove the shift linkage from the shift arm and swing the linkage forward Account for an E clip bushing and washer 4 Loosen the alternator mounting cap screws and remove the alternator...

Page 67: ...cracks seal damage or signs of oil leakage If oil is present locate and repair any leaks Thoroughly clean all oil from the timing belt cover and pulleys Installing 1 Check that the reference mark C o...

Page 68: ...que wrench position the handle 90 to the tensioner tab and apply 14 5 ft lb of torque Tighten the timing belt idler nut securely DE234A DE222A 4 Rotate the engine in the direction of rotation clock wi...

Page 69: ...hose and the coolant bypass hose from the water pump then remove four cap screws securing the water pump and remove the water pump 4 Thoroughly clean all gasket material from the engine block and wat...

Page 70: ...th the outer seal bore DE237 NOTE If there is a groove worn in the crankshaft where the seal contacts press the seal into the bore an additional 2 mm 0 080 in Servicing NOTE The oil pump is a non serv...

Page 71: ...then remove the seat and left side engine cover 2 Disconnect the battery B wire from the alternator then disconnect the voltage regulator control plug in DE519B 3 Loosen the alternator adjuster cap s...

Page 72: ...to be removed from the frame for this procedure FLYWHEEL PTO V BELT HOUSING Removing 1 Remove the transmission see Removing Engine Transmission Transmission in this section 2 Using Drive Clutch Remova...

Page 73: ...k so that the ring gear is free to be driven from the flywheel then using a punch and hammer tap the ring gear off the flywheel DE592 3 Lay the flywheel on a flat surface with the PTO side up then pla...

Page 74: ...a reference on the shift arm them remove the shift arm DE119A 4 Remove the shift shaft housing Account for a gas ket 5 Remove the shift shaft noting the match marks on the drive and driven gear plates...

Page 75: ...illustration DE663B DE663B 10 Remove the output driveshaft assembly A Account for the bearing alignment C ring in the bearing boss next to the output driven bevel gear NOTE Note the location of the be...

Page 76: ...from the transmission case 18 Remove the snap ring securing the output drive bear ing in the right side case then using appropriate bearing drivers remove the appropriate bearings DE169 DE170 Disasse...

Page 77: ...eal DE149 Disassembling Countershaft NOTE Steps 1 21 of the preceding sub sections must precede this procedure 22 Remove the high driven gear then remove the high low shift dog Account for a washer an...

Page 78: ...bearing and bushing DE154 DE155 26 Remove the low gear locking washer then rotate and remove the splined low gear retainer DE184 27 Remove the low gear Account for a washer and the low gear bearing a...

Page 79: ...tion chipping or galling DE143 DE179 4 Inspect roller bearings for chipping missing rollers or discoloration DE178 DE185 5 Inspect drive and driven bevel gears for proper tooth contact chipping or dis...

Page 80: ...r broken spring DE128 11 Inspect bearings for discoloration flaking or rough ness and binding when turning 12 Inspect and thoroughly clean all bearing pockets thread bores and plug openings to remove...

Page 81: ...ven gear bushing and bear ing DE185A 4 Install the reverse driven gear onto the bearing then secure with a splined washer and snap ring NOTE Always install snap rings with the flat sharp side away fro...

Page 82: ...the output shaft until it firmly contacts the spacer DE667A 2 Install the bearing race A and bearing B onto the secondary driven shaft C making sure the bearing locating groove is directed away from...

Page 83: ...ge is 0 127 0 381 mm 0 005 0 015 in Correcting Backlash NOTE If backlash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove a...

Page 84: ...then install the input driveshaft DE179 DE140 DE192A 3 Install the assembled countershaft assembly taking care to position a washer on each end DE142 DE193A 4 Install the reverse shift fork then inst...

Page 85: ...rear bearing with the case groove and install the C ring DE135A DE663D 7 Apply a thin layer of Three Bond Sealant to the mat ing surface of the right side gear case then make sure that the alignment p...

Page 86: ...ly DE121A 11 Using a new gasket install the shift shaft housing and secure with existing cap screws then install the shift arm aligning the mark with the slot Tighten all fasteners securely DE119 12 A...

Page 87: ...ight Side Components in this sec tion 3 Remove the timing belt see Left Side Components in this section 4 Remove the cylinder head assembly see Top Side Components in this section 5 Remove the oil pum...

Page 88: ...l or hammer handle carefully push against the first connecting rod until the piston connecting rod assembly is free of the cylinder bore NOTE If the piston hangs up at the top of the cyl inder it may...

Page 89: ...aft end play at the thrust bearing surface Record this measurement DE435A 17 Mark the main bearing caps and engine block for proper orientation then remove the cap screws securing the main bearing cap...

Page 90: ...om the main bear ing caps and saddles then set the caps aside in order NOTE If main bearing inserts are to be used again mark their locations for correct positioning during installing 3 Using appropri...

Page 91: ...with hot water and dry with compressed air 7 Using a cylinder bore gauge or suitable snap gauge and micrometer measure the cylinder bore at three locations taking measurements at 45 intervals If the c...

Page 92: ...mm 0 020 in sizes Use of undersized bearings will require the crankshaft journals to be machined to the correct size by a qualified machine shop 12 Lightly coat the crankshaft journals with clean oil...

Page 93: ...he corresponding main bearing bore The clearance must be within specifications DE609A DE614A 17 Install the bearing inserts to be used for assembly in the connecting rods then secure the connecting ro...

Page 94: ...that only a qualified machine shop replace bushings 21 Examine the connecting rods for nicks gouges dis coloration and stress lines DE623 22 Examine the piston pin bushing for galling or discol oratio...

Page 95: ...earing inserts into the main bearing saddles making sure the oil holes in the inserts are aligned with the oil galleys in the saddles and the locating tabs are oriented in the reliefs DE376A 2 Install...

Page 96: ...earing caps DE431A 6 Using Main Bearing Seal Installation Tool or 0 07 mm 0 003 in shim stock as shown slide the main bearing cap into position in the main bearing saddle being careful to keep the sea...

Page 97: ...rocedure A Place the oil expander ring in the 3rd bottom ring groove then install the oil scraper ring over the expander making sure the oil scraper ring end gap is not directly in line with the expan...

Page 98: ...DE390 20 While carefully guiding the connecting rod onto the crankshaft journal push or bump the top of the piston until the connecting rod is seated on the crank shaft DE436 21 Apply clean engine oi...

Page 99: ...oil sump and return galleys DE440B DE410 27 Install new O rings on the oil sump and return pipes then apply oil soluble grease on the O rings and place the oil pan into position DE596A 28 Secure the o...

Page 100: ...496 34 The engine is now assembled and ready for connec tion to the transmission secondary transmission 35 Install the engine transmission assembly see Install ing Engine Transmission in this section...

Page 101: ...ectional arrows are present DE479 DE488 6 Secure the driven pulley with a flat washer and nut threads coated with green Loctite 609 then tighten the nut to 125 ft lb NOTE If using a new nut ensure any...

Page 102: ...and secure with four cap screws Tighten to 20 ft lb DE083A 5 Raise the front of the engine and install a cap screw two flat washers and a nut securing the front mount ing bracket to the front engine...

Page 103: ...xhaust pipe and gasket and secure with two copper nuts Do not tighten the nuts at this time DE587 11 Install the muffler and secure to the exhaust pipe with two springs making sure the grafoil seal is...

Page 104: ...the V belt cooling fan assembly then install the V belt cooling boots to the V belt housing DE076A 16 Connect the V belt cooling fan connector DE518A 17 Install the air filter assembly and secure with...

Page 105: ...age to the transmission shift arm and secure with the E clip DE064A 22 Install the front body panel and front rack then install the left and right footrests see Steering Frame Controls 23 Pour the rec...

Page 106: ...ed 3 Fuel filter obstructed 4 Fuel lift pump defective 5 Fuel solenoid valve not opening 1 Clean vent hose 2 Clean replace hose 3 Replace fuel filter 4 Replace pump 5 See Electrical System Fuel Soleno...

Page 107: ...ace pump 7 Replace filter Problem Exhaust smoke dirty or heavy Condition Remedy 1 Oil in the engine overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored scuf...

Page 108: ...back into the fuel return side of the fuel rail and routed back to the fuel filter head where it either recirculates or is returned to the fuel tank via the fuel return hose Fuel flow is shut off when...

Page 109: ...edure REMOVING 1 Remove the right front inner splash panel then remove the V belt cooling boot from the V belt hous ing DE061A 2 Locate the fuel solenoid mounted on top of the fuel filter head then di...

Page 110: ...any pin holes are noted in the fuel screen replace the fuel level sensor assembly 5 Inspect the tank cap and filler neck for chipped or broken threads 6 Inspect the fuel tank mountings for security si...

Page 111: ...t under the left front of the engine then loosen the hose clamp on the coolant bypass hose 3 Remove the hose and allow coolant to drain into the drain pan A funnel or short hose can be used to direct...

Page 112: ...t cover housing to the thermostat housing Account for an O ring and a thermostat INSPECTING 1 Inspect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the the...

Page 113: ...ion Left Side Components Troubleshooting Problem Starting impaired Condition Remedy 1 Fuel contaminated 1 Drain fuel tank and fill with clean fuel Problem Idling or low speed impaired Condition Remedy...

Page 114: ...un times Frequent winch usage snowplowing extended low RPM operation short trips and high amperage accessory usage are also reasons for battery discharge Maintenance Charging NOTE Arctic Cat recommend...

Page 115: ...after it has cooled 7 Once the battery has reached full charge unplug the charger from the 110 volt electrical outlet NOTE If after charging the battery does not perform to operator expectations brin...

Page 116: ...ch component the connector and the switch wiring har ness for resistance RESISTANCE Switch Connector NOTE The brake lever must be compressed for this test Also the ignition switch must be in the OFF p...

Page 117: ...a plug in device located under the seat The glow plug controller relay applies 12 DC volts to the glow plugs in the pre combustion chambers to aid in cold starting Heating time is determined by the E...

Page 118: ...ead contact each end of the fuse holder connector terminals individually 5 The meter must show battery voltage from one side of the connector terminal ends NOTE Battery voltage will be indicated from...

Page 119: ...ion switch to the LIGHTS position 6 Connect the red tester lead to the red wire then con nect the black tester lead to the red black wire 7 The meter must show less than 1 ohm 8 Connect the red tester...

Page 120: ...ith the connector disconnected and on the switch side of the connector RESISTANCE 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the orange wire then connect the black...

Page 121: ...he starter wire from the starter solenoid then remove the two cap screws securing the starter to the V belt housing INSTALLING 1 Place the starter into position in the V belt housing then secure with...

Page 122: ...NG Prior to performing the following tests make sure the alternator belt is properly tightened and the battery is fully charged 1 Using a suitable multimeter select the DC Voltage position then connec...

Page 123: ...the DC Voltage position 2 Connect the red tester lead to one wire then connect the black tester lead to the other wire 3 With the dimmer switch in the LO position test the two outside connectors LO be...

Page 124: ...fuel solenoid see Fuel Lubri cation Cooling Troubleshooting Problem Charging unstable Condition Remedy 1 Battery connections loose or corroded 2 Alternator belt loose 3 Alternator regulator failing 1...

Page 125: ...front drive actuator is located on the left side of the front drive input housing With the engine stopped and the ignition switch in the ON position a momentary whirring sound can be heard each time...

Page 126: ...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...

Page 127: ...shock bolts Account for the lock nuts then move the shocks aside and secure them with a strap AF897D 11 Remove the upper A arm lock nuts and cap screws then remove the A arms AF610D 12 Push the axle s...

Page 128: ...emove it from the frame Disassembling Input Shaft NOTE This procedure can be performed on a rear gear case however some components may vary from model to model The technician should use dis cretion an...

Page 129: ...ion housing in a press and remove the bearing GC011 AF984 KX219 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing sn...

Page 130: ...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 25 ft lb NOTE If a n...

Page 131: ...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...

Page 132: ...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 2 Place the pinion assembly in a beari...

Page 133: ...nt 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 case...

Page 134: ...pattern GC036B 5 Place the Backlash Gauge Tool into the splines of the ring gear and install a dial indicator making sure it con tacts the gauge at a 90 angle and on the index mark GC040 GC039A 6 Zer...

Page 135: ...ash and end play are established the gear case can be assembled see Assembling Differential Assembly in this sub sec tion CC888 Assembling Differential Assembly 1 With the pinion gear and new bearings...

Page 136: ...nly 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...

Page 137: ...differential into position on the frame and install the cap screws washers and new lock nuts Tighten to 38 ft lb Make sure the rubber boot is properly seated on the input yoke CD857 2 Pour 275 ml 9 3...

Page 138: ...er lock KX041 5 Remove the two brake calipers right side only NOTE Do not allow the brake calipers to hang from their cable hose 6 Slide the hub out of the knuckle and set aside 7 Remove the cap screw...

Page 139: ...are serviceable on the axles if any other component is worn or damaged the axle must be replaced 1 Using CV Boot Clamp Tool remove and retain both clamps for assembly purposes CF636 2 Place the white...

Page 140: ...flush to the hex nut NOTE If the cotter pin does not line up always tighten to the next alignment CD027 7 Install the wheel Tighten to 40 ft lb steel wheels or 80 ft lb aluminum wheels 8 Remove the A...

Page 141: ...e thrust button from the gear case cover left hand threads Account for a shim Inspecting 1 Inspect the ring gear for excessive wear missing or chipped teeth or discoloration 2 Inspect the thrust butto...

Page 142: ...n 4 Install the left side rear A arms see Rear A Arms in Suspension Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the cotter pin from the nut NOT...

Page 143: ...th new DOT 4 brake fluid from an unopened container Brake fluid readily absorbs moisture from the air signifi cantly lowering the boiling point This increases the chance of vapor lock reducing braking...

Page 144: ...CTING 1 Clean all caliper components except the brake pads with DOT 4 brake fluid Do not wipe dry 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Periodic Main...

Page 145: ...aliper holder making sure the caliper and holder are correctly oriented NOTE It is very important to apply silicone grease to the O rings and caliper bores prior to assembly PR239C 5 Making sure brake...

Page 146: ...r teeth broken 2 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 bro...

Page 147: ...AF626D 4 Compress the shock absorber spring remove the retainer and remove the spring AF730D CLEANING AND INSPECTING 1 Thoroughly clean all shock absorber components 2 Inspect each shock rod for nick...

Page 148: ...he tie rod end from the knuckle 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...

Page 149: ...AF616D 2 Install the A arm assemblies 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 t...

Page 150: ...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 the cotter pin se...

Page 151: ...onto the drive axle CD009 5 Secure the hub assembly with the nut Tighten only until snug 6 Secure the brake caliper to the knuckle with new patch lock cap screws right side only Tighten the caliper to...

Page 152: ...uctions found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Be sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe...

Page 153: ...place shock absorber 3 Adjust shock absorber preload Problem Suspension too stiff Condition Remedy 1 A arm related bushings worn 2 Shock absorber preload too high 1 Replace bushing 2 Adjust shock abso...

Page 154: ...152 NOTES...

Page 155: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 402...

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