Arctic Cat HDX CREW 2017 Service Manual Download Page 122

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121

GZ004A

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, and spring (differential only).

GC015

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 cover. Account for an O-ring.

XR355



NOTE: If the cover is difficult to remove, pry on the

cover in more than one recessed location.

4. Remove the splined coupler, shifter fork, pin, and

spring of the differential lock assembly and set aside.

Note position of parts for assembling purposes.

XR356

5. Remove the left differential bearing flange assembly

and account for a shim. Mark the shim as left-side.

KX177

KX178

6. Place the differential with the open side down; then

lift the housing off the spider assembly. Account for

shim(s) and mark as right-side.

XR358

Summary of Contents for HDX CREW 2017

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

Page 2: ...r 35 Cargo Box 36 Taillight Assembly 37 Seat 37 Seat Backs 37 Troubleshooting 38 Engine Transmission 39 Troubleshooting 40 Removing Engine Transmission 42 Installing Engine Transmission 45 Servicing E...

Page 3: ...OINT directs the technician to cer tain and specific procedures to promote efficiency and to improve clarity At the time of publication all information photographs and illustrations were technically c...

Page 4: ...Storage Box 8 11 Tilt Sensor Frame 6 in lb 75 STEERING COMPONENTS Part Part Bolted To Torque ft lb N m Steering Wheel Steering Shaft 25 34 Rack and Pinion Assembly Frame 35 48 EPS Rack Coupler EPS As...

Page 5: ...w 13 18 Stator Coil Magneto Cover Existing 11 5 15 Oil Strainer Crankcase 54 in lb 6 Starter Motor Crankcase 10 13 5 Oil Pump Crankcase 8 5 11 5 Water Pump Housing Magneto Cover 8 11 Crankcase Half 6...

Page 6: ...g shaft bushing and plungers of the shock absorbers 7 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken th...

Page 7: ...ontrols headlights taillight brakelight and headlight aim adjust or replace if necessary 8 Check the tire pressure Inflate to recommended pressure as necessary 9 Tighten all nuts bolts cap screws and...

Page 8: ...over and lift it up to expose the 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 Ins...

Page 9: ...adjuster screws must not have pressure on them CHECKING Using a feeler gauge check each valve tappet clearance If clearance is not within specifications loosen the jam nut and rotate the tappet adjus...

Page 10: ...ctric starter until the gauge stops climbing five to 10 compression strokes 6 If compression is abnormally low inspect the following items A Starter cranks engine over B Gauge is functioning properly...

Page 11: ...l Filter Wrench and a ratchet handle or a socket or box end wrench remove the oil filter and discard the O ring NOTE Clean up any excess oil after removing the filter 4 Apply fresh oil to a new filter...

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 recomm...

Page 13: ...ING 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 headligh...

Page 14: ...c brakes at all four wheels CHECKING BLEEDING The hydraulic brake system has been filled and bled at the factory 1 With the master cylinder in a level position check the fluid level in the reservoir I...

Page 15: ...pect the hydraulic brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKING REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatical...

Page 16: ...epress 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...

Page 17: ...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 forward 2 Pinch the V belt together near...

Page 18: ...into position then install the cover and secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighten the cap screws to 48 in lb H1 017 5 Install the s...

Page 19: ...a drop 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 whe...

Page 20: ...cap screws securing the EPS assembly to the frame and tighten to 35 ft lb Install the cap screw and new lock nut in the EPS to rack coupler and tighten to 11 ft lb 5 Connect the two electrical connec...

Page 21: ...re replaceable INSTALLING RACK AND PINION 1 From the left side install the steering assembly rack and pinion to the frame assembly and secure with two cap screws Tighten to 35 ft lb 2 Install the EPS...

Page 22: ...PR528A 5 Install the boot onto the rack and secure with the nylon tie 6 Center the rack in the steering rack assembly and align the white paint line on the pinion with the mark on the rack housing PR7...

Page 23: ...rmly seated then install the snap ring PR292A PR289 2 Install the knuckle to the upper and lower ball joints and secure with the two cap screws Tighten to 35 ft lb PR202 PR203 3 Install the tie rod en...

Page 24: ...ck nuts or 80 ft lb aluminum wheel w chrome nuts 10 Remove the vehicle from the support stand Accelerator Pedal REMOVING Dislodge the throttle cable holding grommet from the actuator arm then remove t...

Page 25: ...eat back seat base and center footrest 2 Remove the cap screw and lock nut securing the shift cable to the shift lever PR924A 3 From under the dash loosen the cable adjuster nut then slide the cable f...

Page 26: ...ly when fully in Park Adjust as necessary 6 Install the center footrest seat base seat back and seat LCD Gauge REMOVING INSTALLING To remove the gauge pull out on one side of it then dis connect the m...

Page 27: ...el and remove the panel PR890A 2 Remove the cap screws securing the outer fender then remove the inner front fenders from both sides of the vehicle 3 Remove the cap screws securing the upper front fas...

Page 28: ...nt bumper From under the hood remove the two cap screws securing the bottom of the front storage box to the front bumper HDX306A 7 Remove the four cap screws and two lock nuts secur ing the front bump...

Page 29: ...r then outer front fenders to the vehi cle Place the front access panel into position and secure with the plastic push pins Install the access cover seal 7 Check and adjust headlight aim see Headlight...

Page 30: ...cure with the push pins 3 Secure the outer fenders to the vehicle using the existing cap screws Floor NOTE First row and Second row will be used to help distinguish additional front and rear seat com...

Page 31: ...e vehicle repeat step 6 then lift the rear of the floor up and lift the floor out of the vehicle HDX350 Cleaning and Inspecting 1 Clean the floor with soap and water 2 Inspect the floor for cracks or...

Page 32: ...rews securing both rear steel kick panels to the frame HDX352A 5 Remove the cap screws securing the center footrest to the frame and support bracket then remove the four cap screws securing the rear f...

Page 33: ...floor out of the vehicle HDX357 Cleaning and Inspecting 1 Clean the floor with soap and water 2 Inspect the floor for cracks or holes Installing 1 Place the front of the floor into position in the veh...

Page 34: ...o the kick panels HDX352A HDX348A HDX347A 7 Install the seat base seat back and both rear side panels HDX351A 8 Use the remaining self tapping screws to secure the floor to the frame then install the...

Page 35: ...s outer fenders first HDX267A HDX268A 3 Remove the cap screws around the perimeter of the dashboard ROV 887 4 From under the dashboard disconnect the accessory plugs override switch drive select switc...

Page 36: ...ve select switch override switch and accessory plugs 5 Install and secure the remaining cap screws around the perimeter of the dashboard including the one behind the center dash pad 6 Install both inn...

Page 37: ...ngs to the cargo box HDX311 4 Lower the cargo box then remove the four cap screws from step 2 5 With the help of an assistant or an adequate lift remove the cargo box from the vehicle Account for four...

Page 38: ...he 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 remo...

Page 39: ...en 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 Tir...

Page 40: ...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 descri...

Page 41: ...lace 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 Camsha...

Page 42: ...y 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 cha...

Page 43: ...C con nector C and TPS connector D HDX136A 5 Wrap the gasline hose connector with a shop cloth then remove the gasline hose connector from the fuel rail HDX138A 6 Loosen the clamp securing the air fil...

Page 44: ...se Remove the cap screw from the shift arm and disconnect the gear position switch connector Slide the gear position switch off the engine HDX251D 11 Disconnect the starter cable from the starter then...

Page 45: ...gas ket in the cylinder head and a grafoil seal at the muf fler HDX286 16 Disconnect the upper and lower coolant hoses HDX158A HDX159A 17 Remove the cap screws and lock nuts securing the rubber couple...

Page 46: ...ht engine brackets to the engine Account for the spacers Discard the lock nuts Installing Engine Transmission NOTE Arctic Cat recommends new gaskets and O rings be installed whenever servicing the veh...

Page 47: ...lower frame brace to 35 ft lb HDX362A 7 Route the throttle cable over the top side section of the left frame brace then secure the wiring harness to the frame HDX410A HDX363A 8 Place a new grafoil ga...

Page 48: ...to the starter motor secure with the nut and tighten securely then secure the engine harness ground wires to the engine with a cap screw and tighten to 8 ft lb HDX149A 13 Properly position the gear p...

Page 49: ...onto the fuel rail HDX138B 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 Pour th...

Page 50: ...move the spark plug and timing inspec tion plug then using a socket and ratchet rotate the crankshaft to top dead center of the compression stroke 1 Remove the two tappet covers CC001D NOTE Keep the m...

Page 51: ...off the camshaft CC013D 8 While holding the chain slide the sprocket and cam shaft out of the cylinder head H1 036 NOTE Loop the chain over the cylinder head and secure it to keep it from falling into...

Page 52: ...D 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 o...

Page 53: ...ving 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 sprin...

Page 54: ...N 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...

Page 55: ...sponding piston diameter 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 cleara...

Page 56: ...ightedge 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 warpa...

Page 57: ...er 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 ex...

Page 58: ...sor 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 remove the piston holder and seat the cylinder firmly on...

Page 59: ...is at top dead center 13 Install the rear cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer CD461 NOTE At this point oil the camshaft journals cam lobes and the...

Page 60: ...ole ATV1027 18 Install the first cap screw threads coated with red Loctite 271 securing the sprocket and tab washer to the camshaft Tighten only until snug CD464 19 Rotate the crankshaft until the sec...

Page 61: ...toms 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 adjus...

Page 62: ...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 Removing Lef...

Page 63: ...s 7 Using an appropriate side case puller remove the side cover Account for a gasket and two alignment pins 8 Remove the nut securing the magneto rotor to the crankshaft then install the magneto rotor...

Page 64: ...to 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 ca...

Page 65: ...s 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 en...

Page 66: ...install the crankshaft position sensor and secure with two cap screws Tighten securely 5 Install the upper cable hold down and secure with a cap screw Tighten securely FI595A Installing Left Side Com...

Page 67: ...asher 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 the shift cam shaft th...

Page 68: ...ap 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 crisscros...

Page 69: ...Driven Pulley C Clutch Cover D Oil Pump 1 Remove the cap screws securing the V belt cover noting the location of the different lengthed cap screws for installing purposes then using a rubber mallet g...

Page 70: ...85 CC596 NOTE Account for and inspect the clutch housing seal CF088A 8 Remove the two cap screws securing the gear posi tion switch then remove the switch 9 Remove the nut left hand threads securing t...

Page 71: ...NSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoes for uneven wear chips cracks or discoloration If any shoe is damaged replace the complete set 2 Inspect the clutch shoes for wear or damage...

Page 72: ...itting Replace as necessary CF378 MD1036 2 Note the roller locations then remove the rollers Check for flat spots or abnormal wear Measure the outside diameter standard measurement is 30 mm If excessi...

Page 73: ...there will be a slight clockwise rotation of the cam This is normal due to spring preload 5 Completely relax the spring until all pressure is removed from the compression yoke then remove the wing nut...

Page 74: ...spect spring ends and spring anchors in cam and movable driven sheave for wear or enlarged spring anchor holes NOTE If any of the components fail the above inspection the driven pulley must be replace...

Page 75: ...d install the compression yoke and wing nut WC414 6 Turn the wing nut clockwise to compress the spring being very careful that the cam correctly engages the fixed driven hub then continue to tighten u...

Page 76: ...all the secondary shaft bearing housing making sure the two alignment pins are properly positioned Tighten the new patch lock cap screws to 28 ft lb CD999 2 Install the oil pump then tighten the screw...

Page 77: ...Tighten to 221 ft lb PR410A 6 Install the clutch cover alignment pins into the crank case apply oil to the cover gasket and install the gasket onto the crankcase 7 Lightly grease the clutch housing s...

Page 78: ...14 Pinch the V belt together near its center and slide the spacer and movable drive face onto the driveshaft Using an appropriate spanner wrench secure the drive face with a new nut threads coated wi...

Page 79: ...ws 3 Using the Crankcase Separator Crankshaft Remover and tapping lightly with a rubber mallet separate the crankcase halves Account for two alignment pins NOTE To keep the shaft gear assemblies intac...

Page 80: ...CC675 7 Note the timing marks on the crank balancer assem bly B gear and crankshaft C gear for assembling purposes then slide the crank balancer gear off the crank balancer Account for the key in the...

Page 81: ...Install a new bearing A onto the secondary driven shaft B making sure the bearing locating groove is directed away from the driven gear splines MT011A 2 Using a suitable press install the driven gear...

Page 82: ...im NOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart After backlash and tooth contact are within specifica tions apply red Loctite 271...

Page 83: ...one web to the outside edge of the other web H1 005 2 Acceptable width range must not exceed specifica tions COUNTERSHAFT GZ281A Disassembling 1 Remove the shift forks noting the positions for assemb...

Page 84: ...e the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer GZ320 GZ319 GZ318A 6 Remove the low driven gear Account for a bearing bushing and thrust w...

Page 85: ...9B GZ320B 3 Install the reverse driven bushing and bearing then install the reverse driven gear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with...

Page 86: ...ng the countershaft assembly account for the washer on each end of the shaft Assembling Crankcase Half 1 Install the secondary drive gear assembly into the crankcase MT014 2 Apply a liberal amount of...

Page 87: ...Place a washer on each end of the countershaft assembly then install the assembly CC674 7 Place a washer on the end of the gear shift shaft then install the shaft assembly making sure the two holes o...

Page 88: ...king occurs 5 From the left side install the remaining 8 mm cap screws two inside the case then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs 6...

Page 89: ...rear seat seat back and seat base then disconnect the battery 3 Remove the air inlet boot between the air filter and throttle body then disconnect the MAP sensor con nector A fuel injector connector...

Page 90: ...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 Gas Tank REMOVING 1 Remove the rea...

Page 91: ...e fuel level sensor for proper operation see EFI Sensors Components in Electrical System INSTALLING 1 Place the gas tank into position in the vehicle then install the inside rear hold down strap PR173...

Page 92: ...lter REMOVING DISASSEMBLING 1 Remove the oil pump from the engine see Remov ing Right Side Components in the Engine Transmis sion section 2 Remove the Phillips head screw on the back side of the pump...

Page 93: ...cloth over the oil cover 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...

Page 94: ...oolant as necessary HDX372A 9 Install the front access panel and the weather strip COOLING FAN Removing 1 Remove the radiator 2 Remove the fan assembly from the radiator Installing 1 Position the fan...

Page 95: ...as an assembly see Removing Left Side Components Troubleshooting CAUTION When installing the thermostat make sure the bleed holes are straight up and down or air will remain trapped causing engine dam...

Page 96: ...If it is ever required these two cable ties be removed replacement cable ties should be installed in the same exact location HDX411A After being in service batteries require regular cleaning and rech...

Page 97: ...imum 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...

Page 98: ...ill 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...

Page 99: ...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...

Page 100: ...d using the RPM function on the speedometer tachometer run at 1300 RPM ignition timing should be 16 BTDC 3 Install the timing inspection plug If ignition timing cannot be verified the rotor may be dam...

Page 101: ...switch NOTE The ignition switch must be in the ON posi tion 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the orange wire then connect the black tester lead to...

Page 102: ...the transmis sion shifted into reverse gear 1 Connect the red meter lead to the red green wire and the black meter lead to a suitable ground then select 2WD on the drive select switch The meter must...

Page 103: ...n 2 Connect the black tester lead to the black wire then connect the red tester lead to the white red wire The meter should show battery voltage 3 With the ignition key in the LIGHTS position the mete...

Page 104: ...ltage is not present troubleshoot the battery connector pins wiring harness fuses or relay If resistance is not present or largely out of specification replace the injector CRANKSHAFT POSITION CKP SEN...

Page 105: ...ghten securely then connect the leads SPEED SENSOR NOTE Prior to testing the speed sensor inspect the three wire connector on the speed sensor for contami nation broken pins and or corrosion 1 Set the...

Page 106: ...ans cover the fuel pump opening Inspecting 1 Inspect the fuel screen and blow clean with low pres sure compressed air 2 Move the float lever and check for free movement The float assembly should retur...

Page 107: ...nt the pump runs for several sec onds and the gas gauge reading is normal 4 Start the engine to verify proper engine operation then shut off the engine and install the seat base seat back and seat TIL...

Page 108: ...r set on DC volt scale Test between the adjustment tool black and red jacks Insert the red lead of the digital volt meter into the red jack of the adjustment tool and the black lead of the digital vol...

Page 109: ...he connector is the black three pin one on the right side below the ignition coil HDX150A NOTE Test the connector coming from the engine 1 Set the meter selector to the AC Voltage position 2 Test betw...

Page 110: ...tive cable to the starter with the nut 3 Connect the battery TESTING VOLTAGE Perform this test on the starter positive terminal To access the terminal slide the boot away NOTE The ignition switch must...

Page 111: ...m will not allow it to start Error codes can be cleared by following the procedures located in the EFI Diagnostic System sub section in this section NOTE If the throttle body ECM TPS or ISC are replac...

Page 112: ...rature Rev Limiter 5000 RPM 230 F Inlet Air Temperature INTAKE WT592 Display Inlet air temperature in Fahrenheit or Celsius DTC P0112 P0113 P0114 Usage Verify correct output of IAT sensor NOTE After e...

Page 113: ...fy speedometer sensor signal from the fol lowing 1 Speed sensor to ECM 2 ECM CAN signal to gauge speedometer odometer 3 ECM CAN signal to EPS DIAGNOSTIC TROUBLE CODES DTC If an EFI or related chassis...

Page 114: ...rted to chassis ground Correct condition P0262 Rear Cylinder Fuel injector Circuit High Injector or interconnect harness shorted to battery power Correct condition P0263 Rear Cylinder Fuel injector Ba...

Page 115: ...ion Coil Primary Circuit Low SG Open Coil or interconnect harness open or shorted to chassis ground Correct condition P2301 Rear Ignition Coil Primary Circuit High Coil or interconnect harness shorted...

Page 116: ...place 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 rectifi...

Page 117: ...ns 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 fr...

Page 118: ...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 Different...

Page 119: ...nting cap screw Account for a lock nut and two washers HDX377A 13 Remove the first row passenger seat center floor board and main floorboard see Floor in Steering Body Controls 14 Remove the six cap s...

Page 120: ...ion housing XR347 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for assem bling purposes XR348 XR352 3 Remov...

Page 121: ...ribs and splines then assemble allowing excess grease to freely escape Slight pressure on the boot will be present during assembly Secure with new clamps NOTE Any time drive splines are separated clea...

Page 122: ...move the dif ferential cover Account for an O ring XR355 NOTE If the cover is difficult to remove pry on the cover in more than one recessed location 4 Remove the splined coupler shifter fork pin and...

Page 123: ...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 t...

Page 124: ...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 t...

Page 125: ...nd back and record the backlash Backlash must be 0 011 0 015 in If backlash is within specifications proceed to Ring Gear End Play If backlash is not within specifications increase shim thickness to i...

Page 126: ...lete unit 3 Assemble the fork and sliding collar into the cover assembly then install the left bearing flange bearing assembly and seat firmly into the cover CF266A CF267A 4 Apply a liberal coat of gr...

Page 127: ...E Prior to installing the seal apply High Per formance 2 Molybdenum Disulphide grease to the seal outside diameter 2 Using Gear Case Seal Installer Tool evenly press the seal into the cover bore until...

Page 128: ...cap screws and lock nuts securing the rubber coupler to each propeller shaft to 50 ft lb then tighten the cap screws and lock nuts securing the carrier bearing assembly bracket to the frame to 35 ft l...

Page 129: ...screws and six lock nuts securing the center rubber coupler to both propeller shafts Note the ori entation of the fasteners HDX378 4 Remove the center propeller shaft and rubber cou pler Note the ori...

Page 130: ...of the shaft and differential input shaft 5 If removed secure the rubber coupler to the rear of the center propeller shaft using new patch lock screws and lock nuts Tighten to 50 ft lb 6 Place the cen...

Page 131: ...necessary 1 Using a clean towel wipe away any oil or grease from the axle components CD019 2 Inspect boots for any tears cracks or deterioration NOTE If a boot is damaged in any way it must be replace...

Page 132: ...ntents of grease from the pack in the bear ing housing INSTALLING REAR DRIVE AXLE 1 Push the axle shaft into the CV coupler to release the lock ring then slide the drive axle into place in the gear ca...

Page 133: ...ne flange HDX277 4 Remove the front and rear cap screws and lock nuts securing the rear gear case to the bracket Account for the washers and their locations Discard the lock nuts HDX278A 5 Remove the...

Page 134: ...ce is as specified remove the ring gear and thrust button then place a drop of red Loctite 271 on the threads and tighten to 8 ft lb left hand threads 4 If clearance is not as specified repeat steps 1...

Page 135: ...the input housing until the seal is flush with the housing HDX384 3 Apply grease to the lips of the oil seal then install the input shaft into the input bearing and housing Install the snap ring HDX3...

Page 136: ...to ON and select LOCK on the drive select switch then place the transmission in park and turn the ignition switch to OFF 2 Remove the cotter pin from the hub retaining plate Discard the cotter pins P...

Page 137: ...tall 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 aluminum wheel w black nuts or 80 ft lb aluminum wheel w...

Page 138: ...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 be returned to se...

Page 139: ...dence of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to...

Page 140: ...brake operation MASTER CYLINDER ASSEMBLY NOTE The master cylinder is a non serviceable component it must be replaced as an assembly Removing 1 Slide a piece of flexible tubing over one of the wheel bl...

Page 141: ...e banjo fittings Installing 1 Secure the master cylinder assembly to the frame with two cap screws and two flange nuts Tighten to 25 ft lb 2 Using new crush washers secure the banjo fittings to the ma...

Page 142: ...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...

Page 143: ...ary 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...

Page 144: ...s and bends INSTALLING 1 Place the shock absorber spring over the shock absorber compress the spring and install the retainer 2 Place bushings and sleeves where appropriate into shock eyelet then inst...

Page 145: ...an all shock absorber components in 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...

Page 146: ...dy HDX342 5 Slowly decompress the spring via the shock spring compressors to remove tension from the spring then remove the spring compressor tool Front A Arms REMOVING 1 Remove the hubs see Drive Sys...

Page 147: ...int mounting hole of all residual Loctite grease oil or dirt for installing purposes 3 Inspect the A arm for bends cracks and worn bush ings 4 Inspect the ball joint mounting holes for cracks or damag...

Page 148: ...coated with red Loctite 271 Tighten to 30 ft lb then install a new cotter pin and spread the pin to secure the nut NOTE During assembly new cotter pins should be installed HDX387 8 Apply grease to the...

Page 149: ...k nuts Tighten to 35 ft lb 3 Tighten the hardware securing the A arms to the frame mounts from step 1 to 45 ft lb 4 Secure the shock absorber to the frame with a cap screw and new lock nut Tighten to...

Page 150: ...s found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Be sure all tires are the specified size and have identical tread pattern Troubleshooting WARNING Make sure...

Page 151: ...150 NOTES...

Page 152: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 902 2016 Arctic Cat Inc Effective June 2016...

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