Arctic Cat HDX 500 2017 Service Manual Download Page 1

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2017

ERVICE

ANUAL

www.arcticcat.com

™

Summary of Contents for HDX 500 2017

Page 1: ...2017 S SERVICE ERVICE MANUAL ANUAL www arcticcat com ...

Page 2: ...nel 34 Muffler 34 Cargo Box 35 Taillight Assembly 36 Seat 36 Troubleshooting 37 Engine Transmission 38 Troubleshooting 39 Removing Engine Transmission 41 Servicing Engine 500 45 Servicing Engine 700 81 Installing Engine Transmission 121 Fuel Lubrication Cooling 126 Throttle Body 126 Gas Tank 127 Oil Pump 129 Liquid Cooling System 129 Troubleshooting 132 Electrical System 133 Battery 133 Electronic...

Page 3: ...ned to depict actual conditions Because Arctic Cat Inc constantly refines and improves its products no retroactive obligation is incurred All materials and specifications are subject to change without notice Product Service and Warranty Department Arctic Cat Inc Specifications NOTE Specifications subject to change without notice MISCELLANY Tire Size front rear 26 x 9R 14 26 x 11R 14 Tire Inflation...

Page 4: ...t 22 01 22 04 mm 17 51 17 54 mm Camshaft Journal Outside right center Diameter left 17 466 17 480 mm 21 959 21 980 mm Camshaft Runout max 0 03 mm Cylinder Head Cover Distortion max 0 05 mm CAMSHAFT AND CYLINDER HEAD 700 Cam Lobe Height min 33 53 mm Camshaft Journal Oil Clearance max 0 04 mm Camshaft Runout max 0 05 mm Cylinder Head Cover Distortion max 0 05 mm Torque ft lb Tolerance 0 15 20 16 39 ...

Page 5: ... Clutch Cover Housing 8 11 Inner CVT Cover 500 Crankcase 8 11 Movable Drive Face 500 Centrifugal Clutch Housing 85 115 Movable Drive Face 700 Centrifugal Clutch Housing 162 220 Starter Clutch Flywheel 26 35 Output Shaft Nut Output Shaft 59 80 Output Yoke Nut 700 Output Shaft 200 270 Stator Coil Magneto Cover New 13 18 Stator Coil Magneto Cover Existing 11 5 15 Oil Strainer Crankcase 54 in lb 6 Oil...

Page 6: ...perform this service if desired 1 Clean the seat cushions with a damp cloth and allow to dry 2 Clean the vehicle thoroughly by washing dirt oil grass and other foreign matter from the entire vehi cle Allow the vehicle to dry thoroughly DO NOT get water into any part of the engine or air intake 3 Either drain the gas tank or add a fuel stabilizer to the gas in the gas tank 4 Clean the interior of t...

Page 7: ...ange the engine transmission oil and filter 5 Check the coolant level and add properly mixed coolant as necessary 6 Charge the battery then install Connect the battery cables making sure to connect the positive cable first 7 Check the entire brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace if necessary 8 Check the tire pressure Inf...

Page 8: ...he pre filter HDX237A 2 Loosen the clamp securing the pre filter HDX235 3 Remove the pre filter assembly and wash thoroughly in warm soapy water then rinse and dry 4 Install and secure with the clamp Tighten securely then install the pre filter cover Air Filter 1 Remove any dust and debris from around the filter housing 2 Unsnap the four spring clip fasteners and remove the air filter cover HDX050...

Page 9: ...rew then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw B While holding the valve adjuster dial in place use the valve adjuster handle and loosen the jam nut then rotate the tappet adjuster screw clockwise until friction is felt C Align the valve adjuster handle with one of the marks on the valve adjuster dial D While holding the valve adjuster handle...

Page 10: ...ely 30 ml 1 fl oz of oil into the spark plug hole reattach the gauge and retest com pression 8 If compression is now evident service the top end see the appropriate Engine Transmission Top Side Components Spark Plug A light brown insulator indicates that the plug and fuel air ratio are correct A white or dark insulator indicates that the engine may need to be serviced To maintain a hot strong spar...

Page 11: ...lter and discard the O ring NOTE Clean up any excess oil after removing the filter 4 Apply fresh oil to a new filter O ring and check to make sure it is positioned correctly then install the new oil filter Tighten securely 5 Install the engine drain plug with a new gasket and tighten to 16 ft lb Pour the specified amount of the recommended oil in the filler hole HDX251B HDX459A 6 Start the engine ...

Page 12: ... drain pan by removing in turn the drain plug from each HDX255 HDX220A 4 After all the lubricant has been drained install the drain plugs and tighten to 45 in lb 5 Pour the appropriate amount of recommended lubri cant into the fill hole 6 Install the fill plug and tighten to 16 ft lb NOTE If the lubricant is contaminated with water inspect the drain plug fill plug and or bladder Driveshaft Couplin...

Page 13: ...KING ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically The geometric center of the HIGH beam light zone is to be used for aim ing 1 Position the vehicle on a level floor so the headlights are approximately 6 1 m 20 ft from an aiming sur face wall or similar aiming surface 0748 733 NOTE There should be an average operating load on the vehicle when adjusting the headlight aim 2 Measu...

Page 14: ... adjust the cable housing to align the shift cable end to the shift arm stud HDX261B 4 Install the E clip then tighten the nuts A and B to 8 ft lb 5 Check each gear shift position for proper gear selection and make sure the proper icon illuminates on the LCD Hydraulic Brake System NOTE This ROV is equipped with hydraulic brakes at all four wheels CHECKING BLEEDING The hydraulic brake system has be...

Page 15: ...ally complete the procedure on the FRONT LEFT bleeder screw PR377C E Repeat steps B and C until the brake pedal is firm 3 Carefully check the entire hydraulic brake system to ensure all hose connections are tight the bleed screws are tight the protective caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If found the...

Page 16: ... enough to safely accelerate the vehicle to 30 mph and to brake to a stop 2 Accelerate to 30 mph then release the accelerator pedal and depress the brake pedal to decelerate to 0 5 mph 3 Repeat procedure 20 times until brake pads are bur nished Checking Replacing V Belt REMOVING 1 Remove the seat seat back and seat base then remove the floor and gas tank 2 Remove the right side storage box 3 Remov...

Page 17: ...sure across the top of the V belt in multiple loca tions using a Vernier caliper Do not squeeze the belt as doing so may produce an inaccurate measurement The V belt must be at least 28 5 mm 500 or 35 0 mm 700 at any point INSTALLING 1 Place the V belt into position on the driven pulley and over the front shaft GZ085 NOTE The arrows on the V belt should point in direction of engine rotation forwar...

Page 18: ...tighten the cap screws with washers to 44 in lb On the 500 tighten the cap screws to 8 ft lb H1 017 5 Install the support tube to the frame then position the intake duct and tube in place Secure with the cap screw lock nut and clamp 6 Install the right side storage box 7 Install the gas tank and floor then install the seat back seat base and seat CAUTION Make sure the movable drive face plate is f...

Page 19: ...op of red Loctite 271 to the threads of the nut and secure the steering wheel Tighten to 25 ft lb NOTE If a new steering wheel is being installed mark the wheel as close as possible to the old wheel mark then check for proper positioning with the front wheels straight forward 2 Install the lock clip on the steering shaft NOTE If the hole in the steering shaft does not align with the slots in the c...

Page 20: ... NOTE The EPS assembly is not a serviceable com ponent and must be replaced as a complete assembly 11 Remove the EPS from the top side INSTALLING STEERING SHAFT EPS ASSEMBLY 1 Install the EPS into position 2 Align the slot in the rack coupler to the notch in the frame front wheels centered PR766A 3 On the non EPS models insert the steering rack cou pler into the pinion shaft using the matching ali...

Page 21: ...tion REMOVING RACK AND PINION NOTE If equipped the EPS assembly must be removed prior to removing the steering assembly 1 Remove the front wheels 2 Remove the cotter pins and nuts securing the tie rod ends to the knuckles then remove the tie rod ends from the knuckles PR301 3 Remove the EPS cradle bracket then remove the cap screws securing the steering rack assembly to the rack bracket and remove...

Page 22: ...ie rod end 3 Using a punch or chisel bend the lock washer away from the flats on the tie rod joint PR780 4 Using an appropriate crow foot and backing wrench remove the tie rod assembly NOTE Tie rods come as a complete assembly No further disassembly is required 5 Remove and discard the lock washer INSTALLING 1 Remove the tie rod end and lock nut from the tie rod then install the tie rod boot onto ...

Page 23: ... knuckle 8 Remove the snap ring securing the bearing in the knuckle then press the bearing out of the knuckle PR289 CLEANING AND INSPECTING 1 Clean all knuckle components 2 Inspect the bearing for pits scoring rusting or pre mature wear 3 Inspect the knuckle for cracks breaks or galling of the bearing surface ASSEMBLING AND INSTALLING 1 Using a suitable press and driver press the bearing into the ...

Page 24: ... molybdenum grease to the hub splines PR290A 5 Install the hub assembly onto the splines of the shaft PR961 6 Using Hub Retaining Wrench secure the hub assem bly with the nut Tighten to 200 ft lb PR256 7 Install the retaining plate NOTE If necessary tighten the hub nut clockwise to allow the retaining plate to sit flush with the hub PR965 8 Secure the brake caliper to the knuckle with the two new ...

Page 25: ...at to remove it then remove the cap screws securing the seat back and seat base to access the throttle body Remove the center and main floorboard panels 3 Measure the threaded installed set length A of the throttle cable housing at the throttle body This thread length will be used to reset the throttle cable free play once the throttle cable has been re routed HDX412A 4 Remove the cap screw s secu...

Page 26: ...able HDX413A 3 From within the front right fender well secure the throttle cable A along the frame behind the radia tor using new cable ties B HDX414A 4 Route the throttle cable A down along the right side of the frame and through the front splash panel Secure using new cable ties as shown B HDX415A 5 Route the throttle cable A toward the engine on the right side of the vehicle Secure using a new ...

Page 27: ...eat base seat back and seat Shift Lever REMOVING 1 Remove the plastic push pin from the shift lever knob then remove the knob 2 Remove the cap screw and lock nut securing the shift lever to the shift cable Discard the lock nut 3 Remove the cap screw and lock nut securing the shift lever to bottom pivot location underneath the dash board Slide the shift lever down and out Discard the lock nut PR924...

Page 28: ...aced connect the new cable to the end of the existing cable and pull the new cable into place INSTALLING 1 Route the cable into position making sure there are no kinks or sharp bends 2 Guide the shift cable into the shift cable bracket Install the cable end to the shift arm stud and secure with a new E clip Secure the adjuster nut to the bracket HDX251C 3 From under the dash guide the shift cable ...

Page 29: ...st be made with the vehicle unloaded Mark the center line of the front tires at the front and rear of the tire then using a tape measure measure and record the distance between the marks at the front and rear The front measurement should be 0 6 mm 0 1 4 in greater than the rear measurement toe out PR087A 1 Center the steering wheel then using an open end wrench to hold the tie rod ends loosen the ...

Page 30: ...rk then release the headlight harness anchors from the front bumper HDX304 HDX305A 5 Remove the cap screws and nuts securing the top side of the radiator to the front bumper Disconnect the radiator fan connector Secure the radiator in place 6 Reference mark then release any remaining harness anchors from the front bumper From under the hood remove the two cap screws securing the bottom of the fron...

Page 31: ...e box to the front bumper Using the previously marked harness anchor locations install the anchors to the front bumper 3 Secure the radiator to the front bumper and connect the radiator fan to the wiring harness 4 Install both headlight assemblies onto the front bumper and secure with the retaining clips Install the headlight adjuster screws HDX304 HDX305A 5 Secure the lower front fascia to the fr...

Page 32: ...en secure with the cap screws Tighten securely Front Fenders REMOVING 1 Remove the four cap screws securing each outer fender to the corresponding inner fender then remove the fenders 2 Remove the push pins securing the front access panel Tilt the access panel back to access the inner fender fasteners PR890A 3 Remove the remaining cap screws securing the inner fender from the inside of the headlig...

Page 33: ...ing forward on the upper rear of the floor board lift the rear part of the floor above the seat locating stud HDX310 NOTE To aid in removing insert a small wood block to hold in position PR164 9 From the opposite side of the vehicle repeat step 8 then lift the rear of the floor up and lift the floor out of the vehicle PR945 CLEANING AND INSPECTING 1 Clean the floor with soap and water 2 Inspect th...

Page 34: ... From under the dashboard disconnect the accessory plugs override switch drive select switch and igni tion switch Note the orientation of the connectors for installing purposes 5 Remove the instrument gauge from the dashboard and disconnect it then remove the cap screws secur ing the steel access plate on the driver s side behind the dashboard Disconnect the headlight switch con nector HDX269 6 Re...

Page 35: ...r of the dashboard including the one behind the center dash pad 6 Install both inner front fenders then install the outer fenders HDX268A HDX267A 7 Install the front access panel hood seal and shift lever knob 8 Align and install the steering wheel see Steering Wheel in this section Belly Panel REMOVING 1 Remove the body screws securing the belly panel to the underside of the frame 2 Remove the be...

Page 36: ...ve the cargo box from the vehicle Account for four pivot housings 6 To remove the tilt box actuator if equipped from the cargo box remove the remaining clip and clevis pin ROV578 CLEANING AND INSPECTING 1 Clean all cargo box components with soap and water 2 Inspect the cargo box for cracks tears and loose hardware 3 Inspect the welds of the cargo box frame for cracking or bending 4 Inspect the car...

Page 37: ...inching and cracking 3 Inspect the bulb for wattage voltage and proper operation INSTALLING 1 Install the new bulb in the socket and place the socket assembly into the taillight housing Twist clockwise to lock 2 Connect the wire connector then install on the ROPS tube and secure with two cap screws and lock nuts Tighten securely Seat REMOVING INSTALLING 1 To remove the seat raise the front of the ...

Page 38: ...ken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure too high 2 Steering linkage worn 3 Cap screws suspension system loose 1 Adjust pressure 2 Replace linkage 3 Tighten cap screws Problem Tire wear rapid or uneven Condition Remedy 1 Wheel hu...

Page 39: ...re most critical to the life of this ROV Proper operation during this break in period will help assure maximum life and performance from the ROV Instruct the customer to follow the proper break in procedure as described in the Operators Manual SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special...

Page 40: ...place fuel injector 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excessive 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replace camshaft Problem Engine noisy Noise seems to come from piston Condition Remedy 1 Piston cylinder worn 2 Combustion chamber ...

Page 41: ...vy Condition Remedy 1 Engine oil overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored scuffed 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil change oil 2 Replace cylinder service rings 3 Replace guides 4 Replace cylinder 5 Replace valves 6 Replace seals Problem Engine lacks power Condition Remedy 1 Valve clearance incorrect 2 Valve springs w...

Page 42: ...X136A 5 On the 500 mark all nylon tie locations then discon nect the harness connectors from the ECT sensor A TPS sensor B ISC sensor C TMAP sensor D and Fuel Injector E PK170A 6 Wrap the gasline hose connector with a shop cloth then remove the gasline hose connector from the fuel rail HDX138A HDX449A 7 Loosen the clamp securing the air filter intake tube to the air filter then remove the mounting...

Page 43: ...e 10 From the left side disconnect the ECT sensor con nector speed sensor connector and spark plug cap HDX461A HDX137A 11 Remove the cap screws securing the shift cable bracket to the engine case Match mark the shift arm to the shift arm shaft then remove the cap screw from the shift arm and disconnect the gear position switch connector Slide the gear position switch off the engine HDX254A HDX251D...

Page 44: ...pe then remove the cap screws securing the exhaust pipe to the cylinder head HDX152A HDX154 15 Mark any nylon cable tie locations for assembly pur poses then disconnect the O2 sensor connector Remove the O2 sensor NOTE The sensor connector is located towards the right side of the battery box under the seat HDX360 16 Remove the two exhaust springs at the muffler then remove the exhaust pipe Account...

Page 45: ...ECT housing FI530B FI537 19 Match mark the drive flanges for assembly purposes Remove the fasteners securing the front and rear engine drive flanges HDX314 HDX361 20 On the 700 remove the four nuts securing the left and right engine brackets to the motor mounts 21 On the 500 remove the four cap screws securing the left and right side cradle brackets to the frame HDX288A Rear 700 Front ...

Page 46: ...onents The technician should use discretion and sound judgment NOTE The engine transmission does not need to be removed from the frame for this procedure Removing Top Side Components A Cylinder Head Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug A and outer magneto cover plug then using an appropriate socket and ratchet rotate the crankshaft counterclo...

Page 47: ...FI612 5 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring FI613 NOTE Care should be taken not to drop the C ring down into the crankcase FI720A 6 Noting the timing marks for installing purposes drop the sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cyl inder head Account for an alignment pin N...

Page 48: ...en remove the two nuts securing the cylinder head to the cylinder FI616 FI617 FI618A FI619A 8 Remove the four cylinder head cap screws and wash ers evenly and in a criss cross pattern FI725A 9 Remove the cylinder head from the cylinder remove the gasket and account for two alignment pins FI623A ...

Page 49: ...to using the puller MD1219 NOTE Support the connecting rod with rubber bands to avoid damaging the rod or install a connect ing rod holder AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section AT THIS POINT To inspect cam chain guide see Servicing Top Side Components sub section AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub secti...

Page 50: ...NOTE Index all valves springs and cotters to their original position when removing When installing all valve components should be installed in their original position 1 Using a valve spring compressor compress the valve springs and remove the valve keepers Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC134D CC136D NO...

Page 51: ...Piston 1 Inspect the piston for cracks in the piston pin boss top and skirt areas 2 Inspect the piston for seizure marks or scuffing If piston is scored or galled replace it with a new one 3 Inspect the perimeter of each piston for signs of blowby indicated by dark discoloration Blowby is caused by worn piston rings excessive carbon in ring grooves or an out of round cylinder Removing Piston Rings...

Page 52: ...C127D 2 Measure the corresponding piston diameter at a point 8 mm 0 3 in above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the larger measurement in step 1 The differ ence clearance must be within specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making ...

Page 53: ...d repair the surface using a cylinder hone see Honing Cylin der in this sub section 3 Place the cylinder on the surface plate covered with 400 grit wet or dry sandpaper Using light pressure move the cylinder in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assembly by continu ing...

Page 54: ...haft on a set of V blocks then position the dial indicator contact point against the shaft and zero the indicator CC283D 2 Rotate the camshaft and note runout maximum tol erance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe height ATV1013A 2 The lobe heights must be greater than minimum specifications Inspecting Camshaft Bearing Journal 1 In...

Page 55: ...he rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crankcase FI710 4 Loosely install the two nuts securing the cylinder to the right side crankcase half NOTE The two cylinder to crankcase nuts will be tightened in step 9 FI622A C Cylinder Head Camshaft D Cylinder Head Cover ...

Page 56: ...ng on the rotor to the marking on the magneto cover FI709 11 While holding the cam chain to the front install the rear cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer Tighten to 11 ft lb FI716 12 With the alignment pin installed in the camshaft and the cam lobes directed down toward the piston place the camshaft in position and verify that the tim ing mark o...

Page 57: ...directed down toward the piston C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned 16 Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole MD1363 17 Apply red Loctite 271 to the first cap screw secur ing the...

Page 58: ...itioned NOTE At this point the rocker arms and adjuster screws must not have pressure on them 25 Install the four top side cap screws with rubber washers then install the remaining cap screws Tighten only until snug FI719 26 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 25 to 8 ft lb 27 Adjust valve tappet clearance see Periodic Mainte nance ...

Page 59: ...FI543 5 Remove the cap screws securing the magneto cover to the crankcase Note the location of the two inter nal cap screws and the two longer cap screws FI596A 6 Remove the magneto cover and account for two alignment pins and the gasket D Rotor Flywheel E Starter Clutch Gear F Starter Motor NOTE Steps 1 6 in the preceding sub section must precede this procedure 7 Remove the nut securing the rotor...

Page 60: ... Drive Gear NOTE Steps 1 10 in the preceding sub sections must precede this procedure 11 Remove the shift shaft noting a washer on each end then remove the cap screw securing the gear shift cam plate and remove the plate from the shaft FI559 12 Remove the shift detent cam arm and spring FI560 13 Remove the snap ring securing the output drive gear to the output shaft and remove the gear noting that...

Page 61: ... chipped surfaces missing rollers or discoloration If any of the above conditions exist replace the starter clutch assembly FI572 REPLACING STARTER CLUTCH ASSEMBLY 1 Remove the cap screws securing the starter clutch assembly to the flywheel then remove from the fly wheel FI570 2 Thoroughly clean the rotor flywheel then install the new clutch and secure with the cap screws after applying a drop of ...

Page 62: ...securing the stator coil two cap screws securing the crankshaft position sen sor and one cap screw from the harness hold down 2 Lift the rubber grommet out of the housing then remove the stator coil crankshaft position sensor Account for and note the position of the harness hold down under the crankshaft position sensor FI590 3 Install the new stator coil assembly and apply blue Loctite 243 to the...

Page 63: ...1 If removed place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three cap screws securely MD1122 2 Install the starter motor and tighten the two cap screws to 8 ft lb 3 Install the shift detent cam making sure the washer is installed MD1086 4 Install the shift detent cam arm and spring 5 Install the gear shift shaft assembly an...

Page 64: ...ion of the two internal cap screws tighten the cap screws in a crisscross pattern to 8 ft lb FI596A 10 Install the water pump drive gear and secure with the nut Tighten to 28 ft lb FI547 11 Install two alignment pins and a gasket on the mag neto cover then install the water pump housing assembly Tighten the cap screws to 8 ft lb FI541A FI539 12 Install the water pump cover with a new O ring and se...

Page 65: ...d duct tube assembly then remove the assembly HDX258A 4 Remove the cap screws securing the support tube to the frame HDX260A 5 Remove the cap screws securing the V belt cover to the inner clutch cover then remove the V belt cover Account for two alignment pins and a gasket FI721A 6 Mark the movable drive face and the fixed drive face for installing purposes then using the Spanner Wrench to hold th...

Page 66: ... driven pulley by turning the cap screw clockwise then remove the V belt KC132 9 Remove the fixed drive face MD1094 10 Use the Spanner Wrench to hold the driven pulley then remove the nut securing the driven pulley assembly Remove the driven pulley assembly HDX450 MD1068 11 Using an impact screwdriver remove the three Phil lips head cap screws holding the air intake plate Remove the air intake pla...

Page 67: ... Assembly E Oil Pump Drive Gear F Oil Pump Driven Gear NOTE Steps 1 13 in the preceding sub section must precede this procedure 14 Remove the one way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes MD1286 15 Remove the left hand threaded nut holding the cen trifugal clutch assembly MD1014 MD1016 16 Remove the cam chain FI630 17 Remove the oil pump drive gea...

Page 68: ...ve the oil pump Account for two alignment pins MD1060 22 Remove the four cap screws securing the oil strainer cap then remove the Phillips head screws securing the oil strainer Account for the O ring MD1337 MD1208 Servicing Right Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE Inspect the clutch shoe for uneven wear chips cracks or discoloration If wear is present replace the clutch assembly AT...

Page 69: ...hoe locks up or turns in both directions the one way clutch must be replaced KC332A INSPECTING OIL PUMP 1 Inspect the pump for damage 2 It is inadvisable to remove the screw securing the pump halves If the oil pump is damaged it must be replaced NOTE The oil pump is a non serviceable compo nent and must be replaced as a complete assembly DRIVEN PULLEY ASSEMBLY NOTE The driven pulley assembly is a ...

Page 70: ...019 5 Install the cam chain NOTE Keep tension on the cam chain to avoid damaging the crankcase boss 6 Place the pin into position install the oil pump drive gear and tighten the cap screw coated with red Loc tite 271 to 63 ft lb MD1017 MD1018 7 Install the clutch shoe assembly on the crankshaft then install the flange nut left hand thread coated with red Loctite 271 Tighten to 147 ft lb NOTE The f...

Page 71: ...tion and secure with the nut threads coated with red Loctite 271 Tighten to 85 ft lb Use the Spanner Wrench to hold the clutch assembly in place MD1068 13 Slide the fixed drive face assembly onto the centrifu gal clutch housing shaft 14 Spread the faces of the driven pulley by threading a V belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow th...

Page 72: ...ft lb KC142A Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Complete Remov ing procedures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion ...

Page 73: ...er to illustration FI639A FI639A 1 Remove the secondary driven shaft assembly A noting the location of the front and rear bearing locating pins and the center bearing locating ring FI660A FI659A FI661A 2 Remove the reverse idler assembly B Account for and note the location of the inner bushing 1 idler shaft 2 and outer washer 3 FI641A 3 Remove the driveshaft C then pull the shift fork locating sha...

Page 74: ...output shaft assembly Account for the output shaft a shim a washer and the nut Servicing Center Crankcase Components SECONDARY GEARS NOTE When checking and correcting secondary gear backlash and tooth contact the universal joint must be secured to the front shaft or false measure ments will occur Checking Backlash NOTE The rear shaft and bevel gear must be removed for this procedure Also always st...

Page 75: ...se half 2 Clean the secondary driven bevel gear teeth of old oil and grease residue 3 Apply a thin even coat of a machinist layout dye to several teeth of the gear 4 Install the secondary driven output shaft assembly 5 Rotate the secondary driven bevel gear several revo lutions in both directions 6 Examine the tooth contact pattern in the dye and compare the pattern to the illustrations ATV 0103 A...

Page 76: ...ptable gap range must be within specifications Measuring Crankshaft Runout 1 Place the 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 H1 003A 3 Zero the indicator and rotate the crankshaft slowly 4 Maximum runout must not exceed specifications NOTE Proceed to check runout on the other end of the cr...

Page 77: ...remove the low driven gear along with the bearing and bushing FI666 FI667 4 Remove the splined washer then remove the circlip securing the high low sliding dog Remove the slid ing dog FI668 FI669 5 Remove the circlip securing the high driven gear then remove a washer the high driven gear along with the bearing and bushing and remove the high driven washer FI670 ...

Page 78: ... ring FI671A FI670 2 Install the high low shift dog 6 on the countershaft and secure with snap ring 7 then install the splined washer 8 FI668A 3 Install the low driven bushing 10 bearing 9 and gear 11 on the countershaft then install splined washer 12 FI667A FI666 4 Place the reverse driven bushing 13 onto the shaft then install the bearing 14 gear 15 and splined washer 16 Secure with a snap ring ...

Page 79: ...E If the output shaft was removed make sure that the proper shim is installed 1 Install the output shaft into the crankcase making sure the two gears shim washer and nut are in the correct order MD1199 MD1079 2 Install and tighten the output shaft flange nut to 59 ft lb Using a punch peen the nut MD1333 3 Apply a liberal amount of oil to the crankshaft bear ing Using a propane torch heat the beari...

Page 80: ...iming marks slide the gear into place FI658 6 Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end install in the crankcase FI652A 7 Place the shift forks into position on the assembled countershaft and install into the crankshaft as an assembly FI662 FI653 8 Align the shift forks to allow engagement with the shift cam then engage the shift forks and...

Page 81: ...the center carrier bearing alignment C ring FI660A FI659A FI661A Joining Crankcase Halves 1 Verify that the two alignment pins A are in place and that both case halves are clean and grease free Apply Loctite 5900 or suitable substitute sealant to the mating surfaces Place the right side half onto the left side half FI639B NOTE Be sure to apply silicone to the inside radius of all cap screw locatio...

Page 82: ...g Left Side Components 96 Installing Left Side Components 98 Right Side Components 101 Removing Right Side Components 101 Servicing Right Side Components 104 Installing Right Side Components 108 Center Crankcase Components 111 Separating Crankcase Halves 111 Disassembling Crankcase Half 112 Servicing Center Crankcase Components 113 Assembling Crankcase Half 119 Joining Crankcase Halves 120 Top Sid...

Page 83: ... valve cover Account for and note the orientation of the cylinder head plug Note the loca tion of the two alignment pins CD206 CD211A 5 Loosen the cap screw on the end of the tensioner then remove the two cap screws securing the ten sioner adjuster assembly and remove the assembly Account for a gasket CC009D 6 Using an awl rotate the C ring in its groove until it is out of the cylinder head then r...

Page 84: ...crew securing the cam chain guide Account for a washer H1 037 10 Remove the five nuts securing the cylinder head to the cylinder CC017D CC018D 11 Remove the four cylinder head bolts CD211 12 Remove the cylinder head from the cylinder remove the gasket and account for two alignment pins then remove the cam chain guide CC020D AT THIS POINT To service valves and cylinder head see Servicing Top Side C...

Page 85: ...gasket and two alignment pins CC024D CC025D CC026D 16 Using an awl remove one piston pin circlip CC032D 17 Using the Piston Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston NOTE It is advisable to remove the opposite side circlip prior to using the puller AT THIS POINT To inspect cam chain guide see Servicing Top Side Components sub section AT THIS POINT To ...

Page 86: ...oving Valves NOTE Index all valves springs and cotters to their original position when removing When installing all valve components should be installed in their original position 1 Using a valve spring compressor compress the valve springs and remove the valve cotters Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC1...

Page 87: ...ON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Inspecting Piston 1 Inspect the piston for cracks in the piston pin dome and skirt areas 2 Inspect the piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or honing oil NOTE If scuffing or seizure marks are too deep to correct with the sandpaper replace the piston 3 Inspe...

Page 88: ...meter at the recommended point above the piston skirt at a right angle to the piston pin bore Subtract this measure ment from the largest measurement in step 1 The difference clearance must not exceed specifica tions Installing Piston Rings 1 Install the oil expander spacer making sure the open end is positioned 90 away from the directional arrow as indicated Install the lower oil control lower ra...

Page 89: ...buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion factor between the head and the straightedge 3 Maximum distortion must not exceed specifications CC141D Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting scoring scuffing warpage and corrosion If marks are found r...

Page 90: ... tern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not available use a lightweight petroleum based oil Thoroughly clean cylinder after honing using soap and hot water Dry with compressed air then immediately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder H1 038 4 If any measurement exceeds the limit replace the cyl...

Page 91: ...e mating area place the cylinder gasket into position then place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase CC026D 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then r...

Page 92: ...d tighten to a final torque of 37 ft lb 11 Tighten the 8 mm nuts from step 9 to 18 ft lb and the 6 mm nuts to 8 ft lb then tighten the two cylinder to crankcase nuts from step 4 securely 12 With the timing inspection plug removed and the cam chain held tight rotate the crankshaft until the piston is at top dead center H1 040 13 Install the rear cam chain tensioner guide into the cylinder head Inst...

Page 93: ...n toward the piston C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned 17 Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole ATV1027 18 Install the first cap screw threads coated with red Loctite 271 secur...

Page 94: ... screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise The adjuster shaft tension will be released in step 25 24 Place the chain tensioner adjuster assembly and gas ket into position on the cylinder and secure with the two cap screws CD469 25 Using a flat...

Page 95: ...ighten the cap screws from step 29 to 8 5 ft lb 31 Adjust valve tappet clearance see Periodic Mainte nance Tune Up 32 Place the two tappet covers into position making sure the proper cap screws are with the proper cover Tighten to 9 ft lb CC001D 33 If removed install the spark plug Tighten securely Left Side Components NOTE For efficiency it is preferable to remove and disassemble only those compo...

Page 96: ...ove the crossover tube from the cylinder head Account for an O ring 5 Remove the two cap screws securing the water pump to the engine then remove the water pump 6 Remove the cap screws securing the left side cover to the crankcase noting the location of the different sized cap screws for installing purposes 7 Using an appropriate side case puller remove the side cover Account for a gasket and two ...

Page 97: ... pin into the crankcase 13 Remove the shift shaft noting the timing marks for assembling purposes Account for two washers PR430A 14 Remove the gear shift cam plate and account for a washer then remove the cam stopper and cam stop per spring Account for two washers PR434A Servicing Left Side Components INSPECTING STARTER CLUTCH GEAR 1 Place the starter clutch gear onto the rotor flywheel and attemp...

Page 98: ...e cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a crisscross pattern Make sure the one way bearing is installed with the notches directed away from the rotor flywheel FI576A FI578 REPLACING STARTER GEAR BEARING 1 Support the starter clutch gear in a press making sure to support the hub around the entire circumference then using a suitable bearing driv...

Page 99: ... for and note the position of the harness hold down under the crankshaft position sensor FI590 3 Install the new stator coil assembly and secure with three new patch lock cap screws Tighten to 13 ft lb 4 Place the stator wire harness hold down into posi tion then install the crankshaft position sensor and secure with two cap screws Tighten securely 5 Install the upper cable hold down and secure wi...

Page 100: ...e facing outward NOTE Once the gears are secured remove the oil passage plug from the crankcase 3 Install the two starter gear shafts then install the two starter gears CD139 H2 045 4 In order on the crankshaft install a washer ring gear key and the magneto rotor Secure with the nut coated with red Loctite 271 Tighten to 105 ft lb CD948A CD940B 5 Install the thrust washer and shift cam plate onto ...

Page 101: ... fresh engine oil then place it into position on the two alignment pins Make sure the outer shift shaft washer is in place PR431A 9 Install the magneto cover and secure with the cap screws Tighten only until snug 10 Place the bushing into position on the crankshaft making sure a new lubricated O ring is inside the bushing Tighten the flange nut to 25 ft lb 11 Using a crisscross pattern tighten the...

Page 102: ...mponents 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 from the frame for this procedure Removing Right Side Components A V Belt Cover B Driven Pulley C Clutch Cover D Oil Pump 1 Remove the cap screws securing the V belt cover noting the location of the different lengt...

Page 103: ...steps 7 13 refer to illustration H1 029A NOTE To aid in installing it is recommended that the assemblies are kept together and IN ORDER H1 029A 7 Using a hydraulic press remove the clutch housing assembly from the clutch cover Account for the left fixed drive spacer and an O ring inside the fixed drive spacer CF085 CC596 NOTE Account for and inspect the clutch housing seal CAUTION Care must be tak...

Page 104: ... spacer CC606 11 Using an impact wrench remove the cap screws securing the final drive carrier bearing housing then remove the housing and account for two alignment pins CD999 12 Remove the snap ring securing the oil pump driven gear then remove the gear noting the direction of the sides of the gear for installing purposes Account for a pin and a washer CD984 CD895A 13 Using an impact driver remov...

Page 105: ...locked in place or rotates both directions the drive assembly must be replaced INSPECTING OIL PUMP 1 Inspect the pump for damage 2 It is inadvisable to remove the screw securing the pump halves If the oil pump is damaged it must be replaced CC446D DRIVE CLUTCH ASSEMBLY Disassembling and Inspecting 1 Slide the sheave plate out of the movable drive sheave Make note of each drive face plate damper or...

Page 106: ...the sheave plate into the movable drive sheave CF381 DRIVEN CLUTCH ASSEMBLY Disassembling 1 Secure the clutch spring compressor base in a work vise attached to a stable work table or work bench WC422A 2 Place the driven pulley assembly onto the base and mark the fixed sheave movable sheave and cam then note the location of the spring anchors in the movable sheave and cam and mark them for assem bl...

Page 107: ...t the sheave faces for cracks grooving or checking WC381 WC383 2 Inspect the cam shoes on the movable driven sheave for chipping excessive scoring or general condition WC384A NOTE Always replace the cam shoes as a complete set 3 Inspect the cam ramp faces for galling scoring or excessive wear WC382 4 Inspect the key and keyways in the cam and fixed driven sheave for excessive wear 5 Inspect the we...

Page 108: ...stall the spring over the hub of the movable driven sheave engaging the spring into the previously marked spring anchor hole WC391A 4 Place the cam over the spring and align the spring tip to the previously marked anchor hole WC753 5 Install the centering bushing into the fixed driven hub then with the sharp side upward place the snap ring onto the assembly and install the compression yoke and win...

Page 109: ...ts flush and clear of the snap ring groove then install the snap ring making sure it is seated properly WC412 WC419 9 Turn the wing nut counterclockwise slowly allowing the cam to contact the snap ring then loosen slightly and tap the cam with a plastic mallet to ensure the snap ring is securely seated WC408 10 Remove the wing nut compression yoke and center ing bushing then remove the driven pull...

Page 110: ...the cap screw threads coated with red Loctite 271 and the washer Tighten the cap screw to 62 ft lb CD992 CD991 4 Grease the driven gear pin and insert it into the shaft Install the washer then install the driven gear noting the direction on the sides of the gear from removing Secure with a snap ring CD985A CD984 NOTE When installed correctly the sides of the drive and driven gears will be flush wi...

Page 111: ...ng assembly into posi tion on the crankcase then secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighten to 10 ft lb H1 023 10 Place the driven pulley assembly into position and secure with the nut Tighten to 162 ft lb CF262 11 Slide the fixed drive face onto the clutch shaft 12 Spread the faces of the driven pulley by threading an M6x1 cap scr...

Page 112: ...e transmission in the frame Complete Remov ing procedures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the right side cap screws securing...

Page 113: ...f the direction of the tabs on the forks for assembling purposes 4 Remove the gear shift shaft G noting the location of the two holes on the end of the shaft Account for a spacer and a washer DE677A 5 Remove the countershaft assembly D Account for a washer on each end of the countershaft CC674 NOTE Do not disassemble the countershaft assem bly unless necessary If necessary see Servicing Cen ter Cr...

Page 114: ...condary drive bearing housing then remove the nut securing the drive bevel gear shaft in the bearing and using a plastic mallet drive the shaft out of the bearing Account for shim shims NOTE Shims should be measured and kept for a starting point in adjusting backlash Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set Up NOTE If the secondary output driven shaft is repla...

Page 115: ...machinist s lay out dye Rotate the shafts through several rota tions in both directions Gear contact should extend from the root to the top of the gear teeth MT016A 6 To adjust tooth contact use the following chart to correctly shim the driven shaft 7 After correct tooth contact is established proceed to Checking Backlash in this sub section Checking Backlash 1 If removed install the secondary dri...

Page 116: ...o the upper connecting rod small end bore then remove the gauge and measure it with micrometer CC290D 2 Maximum diameter must not exceed specifications Measuring Connecting Rod Small End Deflection 1 Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate Position the indicator contact point against the center of the connecting rod small end journal 2 Zer...

Page 117: ...sembling then remove the high driven gear outer washer high driven gear high driven gear bearing and high driven gear inner washer GZ283C 2 Remove the high low driven gear dog H1 042A 3 On the opposite side of the countershaft remove the drive gear then remove the snap ring securing the reverse driven gear dog to the countershaft GZ296 CAUTION Care should be taken to support the connecting rod whe...

Page 118: ...rse driven gear B and needle bearing C H1 044 H1 045A H1 046A 6 Remove the reverse driven washer D then remove the low driven gear E H1 047A 7 Remove the low driven gear needle bearing F then remove the low driven gear washer G H1 048A Assembling 1 From the drive gear end install a thrust washer and bearing then install the low driven gear and washer ...

Page 119: ...r A then secure the reverse driven gear assembly with a new snap ring H1 045A H1 044 4 Install the reverse driven dog A onto the counter shaft and secure with a new snap ring B H1 043A 5 Install the drive gear GZ296 6 From the opposite end of the countershaft install the high low driven gear dog A thrust washer B bearing C high driven gear D and spacer washer E ...

Page 120: ...ke then slide the crankshaft assembly into place CC688 CC689 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft install ing tool 3 Install the crank balancer CD832B NOTE It will be necessary to rotate the crank bal ancer until the counterweight is facing away from the crankshaft then rotate the crankshaft clockwise into the journal area to allow the cran...

Page 121: ...y seated into the shift cams CC669 9 Install the reverse idler gear assembly noting the positioning of the two washers gear bushing and shaft CC668 10 Install the front and rear secondary driven shaft assemblies into the left side of the crankcase making sure the bearing locating pins are toward the top of the crankcase and the bearing C ring is fully seated in the crankcase PR787B 11 Place the oi...

Page 122: ...sticking occurs 9 In a crisscross case to case pattern tighten the 6 mm cap screws from steps 6 7 to 10 ft lb NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs Installing Engine Transmission NOTE Arctic Cat recommends new gaskets and O rings be installed whenever servicing the vehicle 1 On the 700 place the engine spacers in position then using new lock nuts install the...

Page 123: ... exhaust pipe then install the exhaust pipe Secure with two exhaust springs and two cap screws tight ened to 20 ft lb HDX286 HDX154 8 Install the O2 sensor and tighten the sensor to 19 ft lb Connect the harness to the sensor HDX360 9 The positive battery cable must be routed away from the exhaust system and secured with new nylon cable ties in the locations shown ROV 674B 10 Install the forward ex...

Page 124: ...to 8 ft lb HDX149A 13 Properly position the gear position switch on the engine A to A and B to B then secure the shift cable bracket to the engine case and tighten the engine case screws to 8 ft lb Connect the gear posi tion switch connector HDX252A HDX253A 14 On the left side connect the ECT sensor connector 700 spark plug cap and speed sensor connector HDX461A HDX137A 15 Install the throttle bod...

Page 125: ...ngages and locks onto the fuel rail HDX138B HDX449A 19 Connect the MAP sensor connector A fuel injector connector B ISC connector C and TPS connec tor D then install new nylon ties as noted during removing HDX136A 20 On the 500 connect the ECT sensor A TPS sensor B ISC sensor C TMAP sensor D and fuel injector E connectors PK170A 21 Pour the recommended amount of oil and coolant into the engine and...

Page 126: ... battery 23 Install the center skid plate center floorboard and seat base then install the seat back and seat 24 Start the engine and check for leaks allowing to warm up for several minutes then shut the engine off and check engine oil and coolant levels 700 ...

Page 127: ... the OFF position then remove the ignition switch key 2 Remove the seat seat back and seat base then dis connect the battery 3 Remove the air inlet boot between the air filter and throttle body then disconnect the MAP TMAP sen sor connector A fuel injector connector B ISC connector C and TPS connector D HDX366A HDX136A PK170C 4 Remove the screw from the throttle arm cover and remove the cover then...

Page 128: ...nd wait for 10 seconds 3 Release the accelerator pedal and wait an additional 10 seconds 4 Turn the key to the OFF position and allow the gauge to shut off Gas Tank REMOVING 1 Remove the seat seat back seat base and side pan els then remove the floorboard 2 Disconnect the vent hose A gasline hose B and fuel pump fuel level sensor connector C then cap the vent fitting and gas hose fitting HDX259A 3...

Page 129: ...1 Place the gas tank into position in the vehicle then install the inside rear hold down strap PR173 HDX370 2 Install the front hold down strap and secure with the two cap screws Do not tighten at this time HDX368 3 Install the rear hold down strap joining cap screw and nut Do not tighten at this time HDX369A 4 Place the gas cap filler panel into position then if necessary position the gas tank so...

Page 130: ...ransmission sec tion 2 Remove the Phillips head screw on the back side of the pump and separate the pump housing and cover Note the position of the inner and outer rotors and alignment pin for assembly 3 Remove oil pump components CLEANING AND INSPECTING 1 Clean all oil pump components 2 Inspect the rotors for scoring and gouges 3 Inspect the alignment pin driveshaft and driven sprocket for damage...

Page 131: ...er to the radiator two on each side Place a pro tective cloth cover over the oil cooler fins to prevent damage when removing the radiator HDX371A 5 Lift the radiator assembly from the vehicle Account for two upper and two lower rubber mounting grom mets Cleaning and Inspecting 1 Flush the radiator with water to remove any contami nants 2 Inspect the radiator for leaks and damage 3 Inspect all hose...

Page 132: ... Removing 1 Drain approximately one quart of coolant from the cooling system 2 Remove the two cap screws securing the thermostat housing to the cylinder head 700 or thermostat housing 500 Account for a thermostat with seal Inspecting 1 Inspect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the thermo stat for proper operation A Suspend the thermostat in ...

Page 133: ... radiator WATER PUMP NOTE On the 700 the water pump is a non ser viceable component It must be replaced as an assem bly see Left Side Components On the 500 to service the water pump see Servicing Left Side Components Troubleshooting 700 Problem Starting impaired Condition Remedy 1 Gas contaminated 1 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 TPS ...

Page 134: ...ver required for these two cable ties to be removed replacement cable ties should be installed in the same exact location HDX411A After being in service batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life The following procedures are rec ommended for cleaning and maintaining lead acid batter ies Always read and follow instructions provide...

Page 135: ...e NOTE For optimal charge and performance leave the charger connected to the battery for a minimum 1 hour after the Maintenance Charge Indicator D illu minates If the battery becomes hot to the touch stop charging Resume 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 operat...

Page 136: ...F position broken main harness RPM wires defect voltage regulator broken ACG stator wires EPS will auto recover when engine RPM signal returns to normal C1315 Engine RPM Faulty Engine RPM CAN signal received by the EPS incorrect or missing Broken main harness CAN wires or defective ECM EPS will auto recover when engine RPM signal returns to normal C1316 EEPROM Error EPS internal memory error has b...

Page 137: ... lead grounded turn the ignition switch to the ON position The meter must show bat tery voltage 5 Connect the red meter lead to the yellow green wire then with the black lead grounded turn the ignition switch to the START position The starter should engage and the meter must show battery voltage NOTE When the starter is engaged battery voltage will be approximately 10 5 DC volts Ignition Coil The ...

Page 138: ...ion timing cannot be verified the rotor may be damaged the key may be sheared the trigger coil bracket may be bent or damaged or the ECM may be faulty Accessory Receptacle Connector NOTE This test procedure is for either the recepta cles or the connectors VOLTAGE 1 Turn the ignition switch to the ON position then set the meter selector to the DC Voltage position 2 Connect the red tester lead to th...

Page 139: ... Place the new buckle assembly into position then secure using a new cap screw and lock nut Tighten to 60 ft lb Connect the switch and secure to the frame with cable ties in the locations shown HDX454A VOLTAGE Brakelight Remove the front storage tray to access the front wires and switch NOTE The ignition switch must be in the ON posi tion 1 Set the meter selector to the DC Voltage position 2 Conne...

Page 140: ...g a thin flat pry bar or suitable putty knife It is not necessary to remove the dash to remove the switch 2 Using an ohmmeter the following readings must be observed HDX273A PR566A VOLTAGE Drive Select NOTE Voltage tests must be made with the switch and the actuator connected The meter can be con nected at the actuator connector using a break out harness or MaxiClips The front drive actuator must ...

Page 141: ...ellow black and black The LED light and connector are located toward the outside of the headlight assembly and use the color codes white red and black 1 Set the meter selector to the DC Voltage position 2 Set the light switch to the correct position for the affected light then connect the black tester lead to the black wire using a MaxiClip 3 Connect the red tester lead to the yellow black wire hi...

Page 142: ...in either the HI or the LO posi tion NOTE If the meter shows no battery voltage trou bleshoot the battery switches power distribution module or the main wiring harness RELAYS The 4 pin relays are identical plug in type located on the power distribution module Relay function can be checked by switching relay positions The 4 pin relays are interchangeable EFI Sensors Components FUEL INJECTOR Voltage...

Page 143: ...sor signal 5 Connect the red tester lead to the green red wire The meter should read approximately 2 9 DC volts NOTE If the meter does not read as specified replace the sensor MANIFOLD ABSOLUTE PRESSURE INLET AIR TEMPERATURE MAP IAT SENSOR 700 NOTE Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge see EFI Diagnostic System in this section 1 Disconnect...

Page 144: ... new speed sensor into the housing with new O ring lightly coated with multi purpose grease then secure the sensor with the cap screw threads coated with blue Loctite 242 Tighten securely CD071 FUEL PUMP FUEL LEVEL SENSOR The fuel pump and fuel level sensor are not serviceable components If either component fails it must be replaced Testing 1 Turn the ignition switch ON and listen for a momen tary...

Page 145: ...assembly should return to the lower posi tion without force 3 Test the fuel level sensor by connecting a multimeter A to the fuel level sensor leads B then select OHMS The multimeter should show 5 ohms at full fuel position C and 95 ohms at empty fuel position D ATV2116 NOTE If readings are erratic clean the resistor wiper and resistor with clean alcohol and retest If still not correct replace the...

Page 146: ...select DC Voltage on the multimeter and con nect the red tester lead to the orange wire C and the black tester lead to the pink black wire A CD706A 2 Turn the ignition switch to the ON position The multimeter should read battery voltage If battery voltage is not indicated check the 30 amp fuse in the PDM or the 10 amp power fuse wiring harness or the ignition switch 3 Remove the red tester lead an...

Page 147: ... 9 volts replace the battery NOTE The Test Harness must be plugged into the analyzer for testing voltage Always verify battery voltage is at least 4 9 DC volts before testing TPS Testing 1 Remove the left side engine cover then disconnect the three wire TPS connector plug NOTE Prior to testing the TPS inspect the three wire plug connector on the main harness and the three pin plug on the TPS for c...

Page 148: ...h the engine running at a constant 3000 RPM 500 or 5000 RPM 700 all wire tests must be within specification RESISTANCE AC Generator 1 Set the meter selector to OHMS position 2 Test between the three black wires for a total of three tests 3 The meter reading must be within specification Regulator Rectifier The regulator rectifier is located under the seat next to the battery Try to verify all other...

Page 149: ...h momentarily held in the start position the meter must show battery voltage and the starter should operate HDX282 NOTE If the meter showed correct voltage but the starter motor did not operate or operated slowly troubleshoot all starting system components before replacing the starter motor NOTE If the meter showed no battery voltage inspect the main fuse ground connections starter lead battery vo...

Page 150: ...n key in the ON position and wait for 10 seconds 3 Release the accelerator pedal and wait an additional 10 seconds 4 Turn the key to the OFF position and allow the gauge to shut off EFI Diagnostic System DIGITAL GAUGE The digital gauge can be used as a diagnostic tool for many of the DTC s displayed To place the gauge into the diagnostic mode use the following procedure 1 Turn the ignition switch ...

Page 151: ...elsius DTC P0112 P0113 P0114 Usage Verify correct output of IAT sensor NOTE After engine has been running IAT read ings will be higher than outside air temperature due to engine and engine compartment heat as well as intake manifold heating MAP AIR PRESS WT602 Display MAP in millibars and in Hg DTC P0107 P0108 Usage Verify barometric pressure signal correct NOTE Local barometric pressure is given ...

Page 152: ...mal function is corrected however intermittent codes must be cleared as noted in the code chart Code Fault Description Possible Cause Fault Recovery Method C0063 Tilt Sensor Circuit High Sensor or interconnect harness shorted to battery power Correct condition C0064 Tilt Sensor Circuit Low SG Open Sensor or interconnect harness open or shorted to chassis ground Correct condition C1400 Fuel Level S...

Page 153: ...rrect condition P0482 Fan Secondary Left Relay Control Circuit Low SG Open Secondary fan fuse has blown the secondary fan relay has been removed or interconnect harness shorted to chassis ground Correct condition P0483 Fan Secondary Left Relay Control Circuit Relay erratic or intermittent Correct condition P0484 Fan Primary Right Relay Control Circuit High Relay or interconnect harness shorted to ...

Page 154: ...ff On U0155 LCD Gauge to EFI ECM CAN Communication Lost Gauge CAN circuit or interconnect harness intermittent or has failed Correct condition U1000 Vehicle Not Registered or Invalid PIN Entered An invalid registration PIN has been entered Enter the correct registration PIN U1001 Vehicle Not Registered and Vehicle Limits Enabled An invalid registration PIN has been entered Enter the correct regist...

Page 155: ...eplace battery Problem Magneto overcharges Condition Remedy 1 Battery short circuited 2 Regulator rectifier defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifier 3 Clean tighten ground connection Problem Charging unstable Condition Remedy 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier defective 1 Replace lead wire 2 ...

Page 156: ...e actuator runs constantly or makes squealing or grinding sounds the actuator must be replaced REMOVING 1 Select LOCK on the drive select switch then discon nect the connector on the actuator harness Remove the front six cap screws securing the skid plate to the frame 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the actuator WC938A 3 Remove the mounting cap ...

Page 157: ...g the drive select switch several times 7 Secure the wiring harness to the frame with a nylon cable tie then install the inner fender panel 8 Install the cap screws to secure the skid plate to the frame Front Differential REMOVING 1 Remove the hubs see Hub in this section 2 Remove the belly panel 3 Remove the drain plug and drain the gear lubricant into a drain pan then install the plug and tighte...

Page 158: ...ing cap screw Account for a lock nut and washers HDX292 11 Remove the upper differential mounting cap screw Account for a lock nut and two washers HDX377A 12 Match mark the front driveshaft flange to the rubber dampener Remove the three patch lock cap screws and lock nuts Discard the fasteners HDX361A 13 Free the differential assembly from the frame mount ings and separate from the front driveshaf...

Page 159: ... a gasket Remove the fork collar and spring Note the location of all the components for assem bling purposes GC015 XR348 3 Remove the snap rings from the input shaft then remove the input shaft from the pinion housing GC009A 4 Using a seal removal tool remove the input shaft seal Account for a spacer GC010 5 Remove the snap ring securing the input shaft bear ing then place the pinion housing in a ...

Page 160: ...e the input shaft with High Performance 2 Molybdenum Disulphide Grease packing the splines then assemble allowing excess grease to freely escape Grease the pinion housing seal then install the input shaft into the pinion housing and secure with a new snap ring NOTE Any time drive splines are separated clean all splines with parts cleaning solvent and dry with compressed air then lubricate with rec...

Page 161: ...sing XR347 Disassembling Differential Assembly NOTE This procedure can be performed on a rear gear case 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing Account for the coupler fork shuttle shaft with O ring and spring XR352A 2 Using a T 40 torx wrench remove the cap screws securing the differential cover 3 Using a plastic mallet tap lightly to remove the dif ferential ...

Page 162: ...the housing WC430 2 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing XR359 3 Secure the pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar and a bearing CC879 4 Remove any reusable parts from the gear case hous ing then discard the housing and lock collar Assembling Pinion Gear 1 Install the beari...

Page 163: ...th front differ ential or rear drive gear case NOTE All bearings must be installed in the gear case and the pinion properly installed before proceed ing Backlash NOTE Always set backlash prior to any other shimming 1 Install the existing shim or a 0 051 0 055 in shim on the gear case side of the ring gear assembly GC031A 2 Install the ring gear with shim in the gear case then while holding the pin...

Page 164: ...n GC036B 5 Place the appropriate Backlash Measuring Tool into the splines of the ring gear and install a dial indicator making sure it contacts the gauge at a 90 angle and on the index mark GC040 GC039A 6 Zero the dial indicator then while holding the pinion stationary rock the ring gear assembly forward and back and record the backlash Backlash must be 0 011 0 015 in If backlash is within specifi...

Page 165: ... thickness NOTE Once proper backlash and end play are established the gear case can be assembled Assembling Differential Assembly 1 With the pinion gear and new bearings installed place the selected backlash shim on the gear case side of the ring gear with the chamfered side toward the ring gear then install into gear case differential housing GC031A GC020 2 Place the selected end play shim chamfe...

Page 166: ... housing is being installed tighten the cap screws to 28 ft lb 6 Install the shift fork shaft w spring into the housing making sure the shaft O ring is positioned to the inside XR354 7 Install the shift fork assembly making sure the fork leg is facing upward Apply a small amount of oil to the gasket then install the gasket XR353 8 Place the input shaft assembly onto the gear case housing then with...

Page 167: ...9A 2 Install the lower differential mounting cap screw washers and lock nut Tighten the differential to frame cap screws and lock nuts to 42 ft lb HDX292 3 Pour 269 ml 9 1 fl oz of SAE 80W 90 hypoid lubri cant into the differential and install the fill plug Tighten to 16 ft lb 4 Align thepreviously made match marks on the front driveshaft and the rubber coupler then install new Patch lock cap scre...

Page 168: ... Install the belly panel Drive Axles REMOVING REAR DRIVE AXLE 1 Remove the hubs see Hub in this section 2 Remove the cap screw and lock nut securing the knuckle to the upper A arm Discard the lock nut PR962 3 While holding the drive axle stationary pull the top of the knuckle out and down until it is free of the drive axle PR963 4 Place a drain pan under the vehicle to contain any oil leakage then...

Page 169: ...e axle from the CV joint sharply pull back on the axle then slide the boot off of the axle HDX392 NOTE Steps 1 3 can be used to replace the out board boot ASSEMBLING AXLES 1 Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly NOTE Position the end of the clamp opposite the forward rotation of the axle HDX393A NOTE The boot is positioned correctly ...

Page 170: ... nuts or 80 ft lb aluminum wheel w chrome nuts 5 Remove the vehicle from the support stand and release the parking brake INSTALLING FRONT DRIVE AXLE 1 Push the axle shaft into the CV coupler to release the lock ring then position the drive axle in the gear case and steering knuckle then insert the ball joints into the steering knuckles Secure with cap screws tight ened to 35 ft lb 2 Secure the low...

Page 171: ... Install the thrust button with shim into the gear case cover and tighten securely left hand threads GC057A 2 Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge Clearance should be 0 020 0 040 in GC058A 3 If clearance is as specified remove the ring gear and thrust button then place a drop of red Loctite 271 on the thre...

Page 172: ... driver press the bearing from the housing HDX385 Cleaning and Inspecting 1 Wash all parts in parts cleaning solvent and dry with compressed air 2 Clean all gasket material and sealant from mating surfaces 3 Inspect bearings shafts and housing for excessive wear cracks or discoloration Assembling Installing 1 Install a new bearing into the input housing and secure with the snap ring flat side dire...

Page 173: ...ashers Tighten to 42 ft lb 4 Install the rear drive axles then install the brake cali pers and tighten the new patch lock cap screws to 20 ft lb 5 Fill the gear case with the appropriate lubricant then install the left side storage box Hub REMOVING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel s NOTE The jack stands should be placed under the main frame to avoi...

Page 174: ...stud into the hub and thread on an appropriate flange nut PR250 3 Using a socket and ratchet handle tighten the nut until the stud is fully drawn into the hub PR252A INSTALLING 1 Secure the brake disc if applicable to the hub with the four cap screws coated with red Loctite 271 Tighten to 15 ft lb 2 Apply grease to the splines in the hub PR254B 3 Install the hub assembly onto the axle then place t...

Page 175: ...the air sig nificantly lowering the boiling point This increases the chance of vapor lock reducing braking power and increasing stopping distance 3 Remove the brake hose from the caliper and close the bleed screw then remove the caliper 4 Compress the caliper holder against the caliper opposite the O ring side and remove the outer brake pad then remove the inner brake pad NOTE If brake pads are to...

Page 176: ... 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 Maintenance Tune Up Hydraulic Brake System 3 Inspect the brake caliper housings for scoring in the piston bores chipped seal ring grooves or signs of corrosion or discoloration 4 Inspect the piston surface for scoring dis...

Page 177: ... the O rings and caliper bores prior to assembly PR239C 5 Making sure brake fluid does not contact the brake pads compress the caliper holder toward the caliper and install the inner brake pad then install the outer pad PR238 PR239 6 Place the brake caliper assembly into position and secure with new patch lock cap screws Tighten the caliper to 20 ft lb 7 Place a new crush washer on each side of th...

Page 178: ...o the frame PR338 PR336 4 Remove the master cylinder Discard the three crush washers Inspecting 1 Inspect the master cylinder push rod and clevis for wear bending or elongation of clevis holes 2 Inspect the push rod boot for tears or deterioration 3 Inspect the reservoir for cracks and leakage 4 Inspect the brake hose for cracks and deterioration and the condition of the banjo fittings Installing ...

Page 179: ... Replace coupling 4 Replace joint 5 Replace gear s 6 Replace gears pinions 7 Replace fuse drive select switch front drive actuator Problem Braking poor Condition Remedy 1 Pad worn 2 Brake fluid leaking 3 Master cylinder brake cylinder seal worn 1 Replace pads 2 Repair replace hydraulic system 3 Replace seal s Problem Brake pedal travel excessive Condition Remedy 1 Brake fluid low 2 Piston seal cup...

Page 180: ...This vehicle is equipped with adjustable shock assem blies in the front and rear to allow for different driving and loading conditions The front shock absorbers have an adjustment sleeve with five preload adjustment positions that can be turned with the spanner wrench to increase or decrease coil spring tension To adjust the spring force on these shock absorbers rotate the preload adjustment sleev...

Page 181: ...shings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber spring over the shock absorber compress the spring and install the retainer 2 Place bushings and O rings where appropriate into the shock eyelet then install the shock absorbers with two cap screws and new nuts Tighten to 42 ft lb 3 Remove the vehicle from the support stand Rear Shock Absorber Spring 7...

Page 182: ...n parts clean ing solvent 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock rods sleeves bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the spring over the shock body and onto the bot tom spring retainer Using readily available shock spring compressors install the spring compressors onto the spring towa...

Page 183: ...g compressor tool Front A Arms REMOVING 1 Remove the hubs see Drive System 2 Remove the brake hose clamp from the upper A arm then release the anchors from the A arm HDX295A 3 Remove the cotter pin and slotted nut securing the tie rod end to the knuckle then remove the tie rod end from the knuckle 4 Remove the cap screws securing the ball joints to the knuckle PR193 5 Tap the ball joints out of th...

Page 184: ...to the A arm and secure with the snap ring HDX297 2 Install the A arm assemblies into the frame mounts and secure with the cap screws Only finger tighten at this time HDX296 3 Route the brake hose along the upper A arm Secure with hose anchors and the clamp HDX295A 4 Secure the lower eyelet of the shock absorber to the lower A arm Tighten nut to 42 ft lb 5 Secure the A arm assemblies to the frame ...

Page 185: ...Rear A Arms REMOVING 1 With the vehicle in park secure the vehicle on a sup port stand to elevate the wheels 2 Remove the wheel 3 Secure a strap to the top of the rear knuckle and frame This will support the knuckle and axle while the A arms are being removed 4 Remove the cap screws securing the boot guard to the lower A arm 5 Loosen and remove the sway bar link lock nut and cap screw Account for ...

Page 186: ...ten securely 8 Install the wheels and using a crisscross pattern tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb alumi num wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts 9 Remove the vehicle from the support stand Wheels and Tires TIRE SIZE This vehicle is equipped with low pressure tubeless tires of the size and type listed in the Gene...

Page 187: ...ting WARNING Do not operate the vehicle if tire damage exists Problem Suspension too soft Condition Remedy 1 Spring preload incorrect 2 Spring s weak 3 Shock absorber damaged 4 Rear shock absorbers too soft 1 Adjust preload 2 Replace spring s 3 Replace shock absorber 4 Check and adjust air pressure in shocks Problem Suspension too stiff Condition Remedy 1 Spring preload incorrect 2 A arm related b...

Page 188: ...187 NOTES ...

Page 189: ...188 NOTES ...

Page 190: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2261 043 2017 Arctic Cat Inc Effective February 2017 ...

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Arctic Cat HDX 500 2017, Service Manual

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