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Arctic Cat DVX 400 2004, Service Manual

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Arctic Cat DVX 400 2004 Service Manual Download Page 137

2

Front Brake Lever/

Master Cylinder 

Assembly

NOTE: The master cylinder is a non-serviceable

component; it must be replaced as an assembly.

REMOVING

1. Place a shop towel under the brake hose union bolt

and disconnect the brake hose.

SP422

2. Remove the master cylinder assembly; then remove

the reservoir cap (3) and the diaphragm (4). Drain

the brake fluid.

SP423

3. Remove the brake lever (1) and brakelight switch

(2).

SP424

4. Pull the rubber boot (5) out; then remove the circlip

(6).

SP425A

5. Remove the piston (8), secondary cup (7), primary

cup (9), and spring (10).

SP427

INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the pivot bolt securing the brake lever for

wear. 

2. Inspect the brake lever for elongation of the pivot

hole.

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake hose for cracks and deterioration

and the condition of the fittings (threaded and com-

pression).

! CAUTION

Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the ATV.

Summary of Contents for DVX 400 2004

Page 1: ...ATV Service Manual 2004 2004 2004 A A RC C C T T I DVX 400...

Page 2: ...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 because it deals w...

Page 3: ...rmation 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 1...

Page 4: ...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 1...

Page 5: ...032 in Ignition Coil Resistance primary secondary 0 1 1 0 ohm terminal to ground 13 000 20 000 ohms high tension plug cap removed to terminal Ignition Coil Peak primary CDI Voltage More than 130 volts...

Page 6: ...maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area Tighten the gas tank cap securely after filling the tank Genuine Parts When replacement of p...

Page 7: ...10 Store the ATV indoors in a level position Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free riding Arctic Cat recom...

Page 8: ...2 11 Muffler Spark Arrester 2 12 Gas Vent Hoses 2 12 Adjusting Throttle Cable 2 12 Adjusting Engine RPM Idle 2 13 Engine Transmission Oil Filter 2 13 Adjusting Clutch Lever Cable 2 14 Tires 2 15 Stee...

Page 9: ...Engine Transmission Oil Filter R R R Oil Strainer I I C Drive Chain I I A R Clutch I l A Tires Air Pressure I I R Steering Components I I R Coolant Hoses I l R 4 yrs Suspension Ball joint and tie rod...

Page 10: ...tive battery cable then remove the positive cable and the battery vent tube Remove the battery from the ATV Care should be taken not to damage the vent tube 3 Trickle charge the battery at 0 9 amps fo...

Page 11: ...Foam Filter Cleaner p n 0436 194 and Foam Filter Oil p n 0436 195 are available from Arctic Cat 6 Dry the filter 7 Put the filter in a plastic bag then pour in air filter oil and work the filter 8 Cl...

Page 12: ...n loosen the clamp securing the air cleaner to the outlet tube 5 Remove the cap screws securing the air cleaner to the frame 6 Remove the air cleaner from the frame INSTALLING 0739 212 1 Place the air...

Page 13: ...g for the two camshaft end plugs and the valve cover gasket SP121 NOTE The valve tappet clearance specification is different for intake and exhaust valves The clearance should only be checked when the...

Page 14: ...ce NOTE Tappet shims are available in 25 sizes from 2 30 3 50 mm 0 09 0 14 in in 0 05 mm 0 002 in increments 4 Install the selected shim at the valve stem with the numbers facing the tappet Be sure to...

Page 15: ...8 ATV2152...

Page 16: ...9 ATV2153...

Page 17: ...vice valves see Section 3 7 Pour 29 5 ml 1 fl oz of oil into the spark plug hole reattach the gauge and retest compression 8 If compression is now evident service the piston rings see Section 3 Spark...

Page 18: ...cable free play follow this proce dure 1 Slide the rubber boot away then loosen the jam nut from the throttle cable adjuster AL611D 2 Slide the rubber boot away and turn the adjuster until the thrott...

Page 19: ...ace drain pans under the oil tank drain plug 1 and the crankcase drain plug 2 then remove the plugs and drain the oil ATV2027 ATV2028 4 Remove the cap screws securing the filter cover 5 Remove the fil...

Page 20: ...usting Clutch Lever Cable To adjust the cable use the following procedure 1 Pull rubber protective boot away from the cable adjusters 2 Loosen the lock nut then turn the adjuster to obtain 10 15 mm 0...

Page 21: ...ap screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened to specifications For proper to...

Page 22: ...on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when the most intense beam is centered on the verti cal mark 5 cm 2 in below the horizontal mark on the aiming surface ATV2051B...

Page 23: ...compo nents and missing components If replacement or repair constitutes removal see Section 8 Electrical Connections The electrical connections should be checked periodi cally for proper function In...

Page 24: ...the bleeder screw and tighten E Perform steps B C and D on the other FRONT bleeder screw repeating step C until no air bub bles are observed in the bleeder line Make sure that the brake lever is firm...

Page 25: ...dure A Remove the caliper mounting cap screws 1 and the brake pad mounting pins 2 then remove the brake pads Account for the shims SP127 NOTE Do not compress the brake lever after the brake pads are...

Page 26: ...pressed air blow dust and brake pad resi due from the caliper then install new brake pads and secure with the two mounting pins Tighten to speci fications and lock with the tabs on the washer SP117 8...

Page 27: ...to 0 5 mph 3 Repeat procedure on each brake system five times until brake pads are burnished 4 Adjust the parking brake if necessary 5 Verify that the brakelight illuminates when the hand lever is com...

Page 28: ...t 21 pins on the chain and measure the dis tance between the two points If this distance exceeds the service limit of 319 4 mm 12 57 in the chain must be replaced ATV2156 ADJUSTING To adjust the drive...

Page 29: ...screws securing the drive sprocket cover then remove the cover SP134 7 Remove the drive sprocket cap screws and remove the sprocket 8 Install a new drive sprocket then apply red Loctite 271 to the dri...

Page 30: ...SECTION 3 ENGINE TRANSMISSION Table of Contents Engine Transmission 3 2 Specifications 3 2 Table of Contents Removing Disassembling Assembling Installing 3 3 Table of Contents Servicing Components 3 1...

Page 31: ...e ter 21 972 21 993 mm 0 8650 0 8658 in Camshaft Runout max 0 10 mm 0 004 in Cylinder Head Distortion max 0 05 mm 0 002 in Cylinder Head Cover max Distortion 0 05 mm 0 002 in CYLINDER PISTON AND RINGS...

Page 32: ...2 Remove the negative cable from the battery then remove the positive cable Remove the battery hold down then remove the battery 3 Remove the radiator cap then drain the engine coolant 4 Remove the lo...

Page 33: ...oke cable attached then secure the carburetor out of the way sufficiently to enable engine removal 13 Disconnect the two starter leads from the starter and secure them out of the way 14 Remove the eng...

Page 34: ...g C Upper rear Four cap screws C through bolt A with nut and one mounting bracket D Lower rear One nut B and through bolt leav ing two collars D in the frame ATV2158 22 Work the engine forward to clea...

Page 35: ...washers from the driven gear SP152 NOTE If the right side components are to be removed do not remove the rotor flywheel Pro ceed to step 7 4 Using a 27 mm offset box end wrench hold the rotor flywheel...

Page 36: ...Gear E Oil Pump F Shift Shaft G Shift Cam Driven Gear H Balancer Driven Gear and Drive Gear I Neutral Switch 1 Remove the cap screws securing the clutch cover to the crankcase noting the position of t...

Page 37: ...en remove the oil pipe 6 SP163 NOTE If the top side components have not been removed the tensioner and cam chain cannot be removed 9 Remove the oil pump idler gear 7 the oil pump driven gear 8 and the...

Page 38: ...heel and using a 27 mm offset wrench remove the crank balancer driven gear nut then remove the washer driven gear and locater pin ATV2159A 14 Remove the primary drive gear nut washer and pri mary driv...

Page 39: ...nly those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed fr...

Page 40: ...3 then remove the camshaft journal cap screws and journal caps 4 SP182 NOTE Use caution not to drop the alignment pins or the camshaft drive chain into the crank case 4 Remove the four alignment pins...

Page 41: ...ure cannot be done with the engine transmission in the frame Complete Removing procedures for Left Side Right Side and Top Side must precede this procedure NOTE For efficiency it is preferable to remo...

Page 42: ...t pin 5 shift fork shaft 6 reverse lock shaft 7 shift forks 8 and the shift cam 9 NOTE Note the location of each shift fork for assembling purposes SP191 2 Remove the reverse idler gear and shaft then...

Page 43: ...way replacement is necessary VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve faces and valve stem ends for pits burn marks or other signs of abnormal wear NOTE When...

Page 44: ...cifications replace the cylinder head with a new one SP205 Measuring Valve Stem Runout 1 Support each valve stem end with the V Blocks p n 0644 022 then check the valve stem runout using a dial indica...

Page 45: ...e then from top to bottom 4 Maximum wobble deflection must not exceed specifications Measuring Valve Guide Inside Diameter 1 Insert a snap gauge 1 2 way down into each valve guide bore then remove the...

Page 46: ...ithin specifications NOTE Repeat procedure on the remaining exhaust valve CC139D 2 Insert an intake valve seat pilot shaft into one of the intake valve guides Slide the intake valve seat grind ing too...

Page 47: ...rt areas 3 Inspect the piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or honing oil AN135 NOTE If scuffing or seizure marks are too deep to correct with the s...

Page 48: ...be trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chamber being careful not to nick scrape or d...

Page 49: ...ee locations from top to bottom and again from top to bottom at 90 from the first measurements for a total of six measurements The trueness out of round ness is the difference between the highest and...

Page 50: ...nd camshafts 4 Match the width of the plastigauge with the chart found on the plastigauge packaging to determine camshaft to cylinder head journal clearance ATV2161 5 If clearance is excessive measure...

Page 51: ...the starter torque limiter It is not serviceable To check the slip torque of the starter torque limiter use a holding fixture special socket and a torque wrench as shown If the slip torque is not wit...

Page 52: ...r notches If grooves or notches are present replace the hub OIL PUMP Inspecting Servicing 1 Remove the outer rotor 1 inner rotor 2 and the pin 4 then inspect the outer and inner rotors for nicks scrat...

Page 53: ...e the balancer driven gear noting the posi tion of the two pins A and alignment of the two punch marks SP214 Servicing Center Crankcase Components NOTE Whenever a part is worn excessively cracked dama...

Page 54: ...bearing remover to pull the bearing from the crankcase SP218 SP219 6 Install the new bearing using the bearing installer then apply a small amount of red Loctite 271 to the bearing retainer screws an...

Page 55: ...he crankshaft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the indicator contact at point 1 of the crank shaft ATV 1074 3 Zero the indicator and rotate the cran...

Page 56: ...lip has been removed from a shaft it should be discarded and replaced with a new one NOTE When assembling the transmission shafts attention must be given to the position of the washers and circlips Th...

Page 57: ...eshaft 6 In order install the reverse driven bushing reverse driven gear washer and circlip onto the driveshaft Make sure the oil hole in the reverse driven bushing aligns with the hole in the drivesh...

Page 58: ...ft side on the drive shaft NOTE The driveshaft is now completely assem bled for installation COUNTERSHAFT Disassembling 1 Remove the 2nd drive gear and washer from the countershaft CC204D 2 Remove the...

Page 59: ...ll the 4th drive washer and 4th drive gear onto the countershaft CC201D 5 Install the 2nd drive gear and washer onto the countershaft CC204D NOTE The countershaft is now completely assembled for insta...

Page 60: ...heck to be sure that the gears all engage normally then shift the transmission into neutral 7 Verify that the two crankcase half alignment pins 1 are in place SP226 NOTE Prior to joining crankcase hal...

Page 61: ...Gear NOTE It will be necessary to install the starter driven gear starter one way clutch and the rotor flywheel on the left side prior to installing right side components This is done to provide a mea...

Page 62: ...e crank bal ancer driven gear nut to specifications ATV2169 SP236A C Shift Cam Driven Gear D Oil Pump E Cam Chain NOTE Steps 1 5 in the preceding sub section must precede this procedure 6 Install the...

Page 63: ...gear aligning the pin 1 with the groove 2 and install the circlip SP240 SP241 10 Install the cam chain 1 onto the sprocket then install the cam chain tensioner and tighten the mounting bolt 2 to spec...

Page 64: ...f 122 5 mm 4 82 in first Two dif ferent types of drive plates are used They are the one with the 122 5 mm 4 82 in inside diameter and seven with an inside diameter of 116 0 mm 4 5 in SP247 16 Referrin...

Page 65: ...1 contacts 2 and a new O ring 3 then install the neutral switch and tighten the Allen head cap screws to specifications SP252A 2 Install the starter driven gear 1 dowel pins 2 and a new gasket 3 then...

Page 66: ...om dropping into the crank case then install the piston piston pin and a new circlip with the punch mark 1 on the piston directed toward the exhaust side SP256 SP257 5 Apply engine oil to the sliding...

Page 67: ...eding sub section must precede this procedure 8 Install the cylinder head on the cylinder 9 Lightly oil the threads of the 10 mm cap screws and the washers then install and tighten in two steps to spe...

Page 68: ...ll the alignment pins 1 and cam chain guide then install the camshaft journal holder marked EX on the exhaust camshaft and the camshaft journal holder marked IN on the intake camshaft SP265 17 Making...

Page 69: ...ing sequence A Lower rear One cap screw and nut with two spacers Tighten only until snug B Upper rear Loosely fasten the engine mount to frame cap screws then install the cap screw w nut and flat wash...

Page 70: ...g connectors to the alternator lead wire coupler 3 and the neutral start lead coupler 4 then connect the starter cables SP277 9 Connect the reverse gear selector cable 6 then install the cable bracket...

Page 71: ...le first and the negative cable last 17 Install the seat making sure it locks into position CAUTION If the engine had a major overhaul or if any major part was replaced proper engine break in procedur...

Page 72: ...r 4 6 Throttle Cable Free Play 4 6 Engine RPM Idle 4 7 Gas Tank 4 7 Fuel Valve 4 8 Gas Vent Hoses 4 8 Oil Flow Chart 4 9 Oil Filter Oil Pump 4 10 Testing Oil Pump Pressure 4 10 Oil Tank 4 11 Liquid Co...

Page 73: ...Valve 10 Ring 11 Spring 12 Washer 13 Jet Needle 14 O Ring 15 Washer 16 Pilot Screw 17 Spring 18 Main Jet 19 Ring 20 Jet Holder 21 Jet 22 Pin 23 Needle Valve Assy 24 O Ring 25 Needle Jet 26 Plunger As...

Page 74: ...er Account for the O ring 7 SP279 7 Disconnect the throttle cable from the actuator arm then loosen the outer jam nut 6 securing the throttle cable to the carburetor body and route the cable out of th...

Page 75: ...disassembling procedures SP287A 6 Secure the needle jet holder with a wrench then remove the main jet 7 Remove the needle jet holder then remove the pilot jet and the starter jet 8 Remove and install...

Page 76: ...he O ring is properly positioned then secure with the Phillips head screws 6 Position the spring and primer diaphragm assembly lip toward the carburetor onto the carburetor then secure the assembly wi...

Page 77: ...rtion 10 Inspect all jets for obstructions or damage NOTE If the pilot jet is obstructed the mixture will be extremely lean at idle and part throttle oper ation 11 Inspect the carburetor mounting flan...

Page 78: ...spect all hoses for cracks or leaks 3 Inspect fuel valve tank cap and tank for leaks holes and damaged threads INSTALLING 1 Place the gas tank into position on the frame then install the cap screws Ti...

Page 79: ...2 Remove the two nuts securing the fuel valve then remove the valve Account for the gasket 3 Inspect the gasket and fuel valve tank mating sur faces for damage or deterioration 4 Inspect for and remo...

Page 80: ...9 Oil Flow Chart ATV2180...

Page 81: ...ctic Cat Engine Tachometer p n 0644 275 to the engine 2 Remove the oil galley plug then connect the Oil Pressure Gauge p n 0444 039 to the galley using an appropriate adapter SP004A NOTE Some oil seep...

Page 82: ...rs are service able then install the tank onto the frame and tighten the cap screws securely SP291 2 Install new O rings to the upper and lower tank fit tings then secure the fittings to the tank and...

Page 83: ...eck AN604D Radiator 0739 218 REMOVING 1 Drain the coolant from the engine then remove the seat and body see Section 8 2 Disconnect the negative battery cable then discon nect the positive cable 3 Remo...

Page 84: ...ant from the cooling system 2 Remove the hose clamp securing the upper coolant hose to the thermostat housing then remove the ther mostat housing and the thermostat SP294 INSPECTING NOTE Whenever a pa...

Page 85: ...SP297 3 Remove the cap screws securing the clutch cover then depress the brake pedal and remove the clutch cover SP298 4 Remove the water pump case then remove the cir clip 1 water pump driven gear 2...

Page 86: ...onents in cleaning solvent 2 Inspect the impeller shaft for corrosion or damage ASSEMBLING 1 Place the new oil seal into the housing then using a seal driver gently tap the seal down until it is fully...

Page 87: ...s tem with the recommended amount of coolant AN604D NOTE While the cooling system is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engi...

Page 88: ...olant should be between upper and lower level marks Cooling Fan Thermo Switch REMOVING 1 Drain the coolant in the radiator to a point below the lower temperature switch 2 Disconnect the cooling fan th...

Page 89: ...18 NOTES...

Page 90: ...ature and Cooling Fan Switches 5 4 Fan Motor 5 4 Fuse Holder 5 4 Fuse 5 5 Ignition Coil 5 5 Indicator Lights 5 6 Ignition Switch 5 7 Handlebar Control Switches 5 7 Neutral Switch 5 8 Clutch Lever Posi...

Page 91: ...always verify first that the fuse is good that the bulbs are good that the con nections are clean and tight that the battery is fully charged and that all appropriate switches are activated NOTE For...

Page 92: ...AR621D 3 When the pedal is depressed the meter must show less 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...

Page 93: ...volt D C power supply then connect the black red wire from the fan connector to ground The fan should operate Fuse Holder The fuse and a spare are located on the starter relay under the seat SP032A 1...

Page 94: ...ton 5 The meter reading must be within specification NOTE If the voltage is not as specified inspect the main wiring harness connectors source charge coil magneto rotor and magnets magneto rotor key o...

Page 95: ...D C Voltage position 2 Connect the red tester lead to the orange wire then connect the black tester lead to ground 3 The meter must show battery voltage NOTE This is the only voltage test for all ind...

Page 96: ...the OHMS position 2 Connect the red tester lead to the orange white wire then connect the black tester lead to the black wire 3 With the starter button depressed the meter must show less than 1 ohm 4...

Page 97: ...battery post then connect the black tester lead to the nega tive battery post 3 With the engine running at a constant 5000 RPM with the headlights on the meter must be within specification NOTE If vo...

Page 98: ...nect the black tester lead to the white wire 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Starter Motor REMOVING DISASSEMBLING 0739 228 1 Disconn...

Page 99: ...ground hack saw blade Do not undercut any deeper than the orig inal groove which can be seen by looking at the end of the commutator 9 Using a caliper measure the undercut Maximum undercut groove mus...

Page 100: ...switch must be in the ON position the emergency stop switch in the RUN position the reverse lever on manual transmis sion models in the FORWARD position and the shift lever on automatic transmission m...

Page 101: ...s sub section NOTE If the charge coil test is within specifica tions replace the regulator rectifier Headlights The headlight are halogen bulbs with two wire plug connectors The headlight housing cont...

Page 102: ...D C Voltage position 2 Connect the red tester lead to the black white wire then connect the black tester lead to the white black wire 3 With either brake applied the meter must show bat tery voltage...

Page 103: ...14 WIRING DIAGRAM Harness p n 3509 007 Insert Fold Out 0739 430...

Page 104: ...1 SECTION 6 DRIVE SYSTEM Table Of Contents Drive System 6 2 Rear Drive Assembly Schematics 6 2 Rear Drive Axle 6 3...

Page 105: ...nd lock the parking brake then remove the wheels 3 Loosen but do not remove the four cap screws on the swing arm then turn the adjuster nut counter clockwise to slacken the chain KEY 1 Hub 2 Wheel 3 N...

Page 106: ...e brake disc from the flange SP316 NOTE It is not necessary to remove the right side axle nut SP317 NOTE Do not attempt to remove the brake disc flange The axle and brake flange are an assembly 7 Remo...

Page 107: ...9 2 Clean the axle housing and inspect for cracks elon gated holes and wear in bearing bores INSTALLING BEARINGS 1 Pack the new bearings with a good quality wheel bearing grease then install the right...

Page 108: ...ing the following formula due to the offset of the special tool used to tighten the axle nuts ATV2188 SP323 T Torque wrench reading to be calculated Ts Specified torque value 130 ft lb Ls Tool offset...

Page 109: ...6 NOTES...

Page 110: ...1 SECTION 7 SUSPENSION Table Of Contents Front and Rear Suspension Assembly Schematics 7 2 Shock Absorbers 7 2 Swing Arm 7 5 Front A Arms 7 10 Wheels and Tires 7 15...

Page 111: ...ront Arm Assy 2 Bearing 3 Bearing 4 Grease Fitting 5 Spacer 6 Dust Seal 7 Cap Screw 8 Nut 9 Spacer 10 Spacer 11 Cap Screw 12 Dust Seal 13 Spacer 14 Guard 15 Screw 16 Rear Arm 17 Spacer 18 Cap Screw 19...

Page 112: ...the retainer 2 Install each shock absorber to the frame and A arm with cap screws and nuts Tighten all nuts to specifi cations 3 Remove the ATV from the support stand REMOVING REAR SHOCK 1 Secure the...

Page 113: ...orber in position then install the upper and lower cap screws and nuts 2 Tighten the upper nut 1 and the lower nut 2 to specifications SP332A 3 Install the rear arm lower cap screw and nut then tighte...

Page 114: ...2 Turn the adjuster 16 clicks counterclockwise for the standard setting Compression 1 Turn the upper damping force adjuster screw fully clockwise SP337 2 Turn the adjuster two full turns counterclockw...

Page 115: ...orber then remove the rear wheels 5 Remove the axle housing see Section 6 6 Remove the brake hose guide 1 then remove the parking brake cable guide 2 SP341 SP342 7 Remove the swing arm pivot nut then...

Page 116: ...or wear or damage If any defect is found they must be replaced 2 To inspect swing arm bearings and bushings insert the spacer 1 into the bearing 2 and bushing 3 then check for excessive play by moving...

Page 117: ...must be replaced SP351 SP352 6 Remove the dust seals then using a suitable bearing puller and slide hammer remove the defective bear ing NOTE Removed bearings must be replaced with new ones SP353 SP3...

Page 118: ...marks directed towards the outside then lubricate the bearing bushings and seal lips with multipurpose grease SP358A 3 Apply multipurpose grease to the lip of the dust cov ers then install the dust c...

Page 119: ...A 7 Install the rear arm bolts and nuts then tighten the nuts 3 and 4 to specifications SP365 8 Install the rear arm guard and the swing arm guard Front A Arms REMOVING 1 Secure the ATV on a support s...

Page 120: ...end to the knuckle then remove the tie rod end from the knuckle SP369 7 Remove the brake hose clamp 1 then remove the front bumper assembly 3 SP370 SP371 8 Remove the shock absorber lower mounting cap...

Page 121: ...sed air If any damage or excessive wear is detected the knuckle must be replaced SP375 2 Inspect the ball joint for boot damage or wear Remove the circlip and replace the ball joint if dam age is foun...

Page 122: ...then clean all parts in parts cleaning sol vent SP382 NOTE All bearings spacers and seals that are removed must be replaced with new ones INSTALLING 1 Using a bearing installer install the ball joint...

Page 123: ...bores then install the arms to the steering knuckle and tighten the ball joint nuts to specifica tions Install new cotter pins NOTE During assembly new cotter pins should be installed SP388A SP390 6 I...

Page 124: ...a support stand to elevate the wheels 2 Remove the wheels NOTE Keep left side and right side wheels sepa rated for installing them on their proper sides SP054 CLEANING AND INSPECTING NOTE Whenever a p...

Page 125: ...and have it repaired professionally NOTE Be sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe in and toe out and adjust as necessary see Section 8 4 T...

Page 126: ...1 SECTION 8 STEERING FRAME Table Of Contents Steering Post Tie Rods 8 2 Measuring Adjusting Toe In Toe Out 8 7 Body 8 8...

Page 127: ...on switch 5 with the parking brake engagement pin A depressed Remove the handlebar switch assem bly 6 SP396 4 Remove the steering head cover 7 then remove the harness clamps 8 KEY 1 Steering Post 2 Du...

Page 128: ...the engine oil from the oil tank then drain the coolant from the radiator 7 Remove the radiator assembly 1 See Section 4 SP399 8 Remove the two fasteners then remove the oil hose protector SP400 9 Di...

Page 129: ...ws SP406 SP407 SP408 12 Remove the hose and cable guide then remove the steering post holder 13 Remove the steering post 9 then remove the dust seals 10 and the steering post holder half 11 SP409 14 R...

Page 130: ...y multipurpose grease to the steering post and dust seal then install the dust seal 1 to the steering post SP411 2 Install a new O ring 2 and the dust seal into the steering housing then install the w...

Page 131: ...e the handlebar 1 handlebar holder 2 and steering head cover bracket 3 with the stepped end of the lower holder A directed rearward then finger tighten the cap screws ATV2202 9 Adjust the handlebar in...

Page 132: ...ad using a suitable means of mea suring centering then adjust tire pressure to specifications 2 Place suitable ballast of 75 kg 165 lb of weight on the seat then loosen the lock nuts 1 and 2 on each t...

Page 133: ...support mounting nuts SP098 3 Remove the front fender support brackets from the frame leaving them attached to the body SP099 4 Remove the two nuts from the plastic studs on the upper forward support...

Page 134: ...ody over the handlebar and rotate into nor mal mounting position 2 Seat the two upper forward support studs and the rear fender support studs into the brackets then install the nuts and tighten secure...

Page 135: ...10 SP106 SP107 7 Install the starter relay then install the seat making sure it is locked securely front and rear...

Page 136: ...TION 9 CONTROLS INDICATORS Table Of Contents Front Brake Lever Master Cylinder Assembly 9 2 Rear Brake Pedal Master Cylinder Assembly 9 3 Throttle Control 9 5 Gearshift Pedal 9 6 Reverse Selector Lock...

Page 137: ...Pull the rubber boot 5 out then remove the circlip 6 SP425A 5 Remove the piston 8 secondary cup 7 primary cup 9 and spring 10 SP427 INSPECTING NOTE Whenever a part is worn excessively cracked or dama...

Page 138: ...ning with the upper clamp bolt tighten the mounting bolts to specifications 5 Connect the brake hose union bolt 1 to the master cylinder then with the stopper against the master cylinder tighten the b...

Page 139: ...sh all master cylinder components in new brake fluid before assembling Do not dry components 1 Apply brake fluid to the master cylinder bore then install the piston with cups 2 Install the push rod an...

Page 140: ...the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm to the throttle control lever AF677D 4 Remove the actuator arm and account for a bushing...

Page 141: ...the pedal for first gear and reverse gear and lifting up on the pedal for second through fifth gear The ratchet mech anism makes it impossible to upshift or downshift more than one gear at a time Reve...

Page 142: ...1 SECTION 10 AIDS FOR MAINTENANCE Table Of Contents Torque Specifications 10 2 Torque Conversions 10 3 Tightening Torque General Bolts 10 3...

Page 143: ...ar Brake Caliper 2 3 16 5 Front Brake Pipe Nut Brake Line Junction Block 1 6 11 5 Brake Caliper Rear Swing Arm Housing 2 6 19 Brake Pad Mounting Pins Caliper 1 8 13 Rear Master Cylinder Push Rod Lock...

Page 144: ...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 1 1...

Page 145: ...1 SECTION 11 TROUBLESHOOTING Table Of Contents Engine 11 2 Fuel System 11 7 Electrical 11 8 Steering Suspension 11 10 Brakes 11 11...

Page 146: ...valve Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Carburetor jets obstructed 5 Valve clearance out of adjustment 1 Clean plug 2 Replac...

Page 147: ...ism Problem Transmission will not shift Condition Remedy 1 Gearshift cam broken 2 Gearshift forks distorted 3 Gearshift shaft worn 4 Clutch cable out of adjustment 5 Reverse selector cable adjusted im...

Page 148: ...p incorrect 9 Carburetor jets obstructed 10 Float level out of adjustment 11 Air cleaner element obstructed 12 Oil in the engine overfilled contaminated 13 Intake manifold leaking air 14 Cam chain wor...

Page 149: ...et 2 Clean outlet 3 Adjust screw 4 Adjust valve 5 Adjust float height Problem Medium or high speed impaired Condition Remedy 1 Main jet obstructed 2 Needle jet obstructed 3 Throttle vacuum piston not...

Page 150: ...emedy 1 Lead wires shorted open loose at terminals 2 Stator coils magneto grounded open 3 Regulator rectifier defective 4 Cell plates battery defective 1 Repair tighten lead wires 2 Replace stator coi...

Page 151: ...rame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pres...

Page 152: ...crews Problem Braking poor Condition Remedy 1 Pad worn 2 Pedal free play excessive 3 Brake fluid leaking 4 Hydraulic system leaking air 5 Master cylinder brake cylinder seal worn 1 Replace pads 2 Adju...

Page 153: ......

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