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Arctic Cat PROWLER XT 2014, Service Manual

The Arctic Cat PROWLER XT 2014 is a high-performance off-road vehicle built to tackle rugged terrains with ease. To ensure the best maintenance and repair, a comprehensive Service Manual is available for download, completely free. Get your hands on this essential manual at manualshive.com and enhance your off-roading experience.

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TABLE OF CONTENTS

General Information ...................................................... 2

General Specifications ...................................................... 2
Torque Specifications ........................................................ 3
Torque Conversions (ft-lb/N-m) ......................................... 4
Gasoline - Oil - Lubricant .................................................. 4
Genuine Parts ................................................................... 5
Preparation For Storage.................................................... 5
Preparation After Storage ................................................. 6

Periodic Maintenance ................................................... 7

Periodic Maintenance Chart.............................................. 7
Lubrication Points.............................................................. 8
Air Filter............................................................................. 8
Valve/Tappet Clearance .................................................... 8
Testing Engine Compression ............................................ 9
Spark Plug(s) .................................................................. 10
Muffler/Spark Arrester..................................................... 10
Engine/Transmission Oil - Filter ...................................... 11
Front Differential - Rear Drive Lubricant ......................... 12
Driveshaft/Coupling......................................................... 12
Nuts/Bolts/Cap Screws ................................................... 12
Headlight/Taillight-Brakelight........................................... 13
Shift Lever (XT/XTZ) ....................................................... 13
Shift Lever/Shift Cable (XTX) .......................................... 14
Hydraulic Brake System.................................................. 15
Parking Brake (XT/XTZ).................................................. 16
Burnishing Brake Pads.................................................... 19
Checking/Replacing V-Belt.............................................. 19

Steering/Frame/Controls ............................................ 21

Steering Assembly (XT) .................................................. 21
Electronic Power Steering (EPS) (XTX/XTZ) .................. 23
Steering Assembly (XTX/XTZ) ........................................ 26
Steering Wheel ............................................................... 27
Upper Steering Shaft ...................................................... 28
Lower Steering Shaft Assembly ...................................... 29
Steering Knuckles ........................................................... 30
Checking/Adjusting Front Wheel Alignment .................... 32
Front Bumper Assembly.................................................. 33
Hood ............................................................................... 33
Fenders ........................................................................... 34
Floor................................................................................ 34
Belly Panel ...................................................................... 35
Accelerator Pedal............................................................ 35
Shift Lever (XT/XTZ) ....................................................... 35
Shift Lever (XTX)............................................................. 36
LCD Gauge/Indicator Lights............................................ 36
Exhaust System .............................................................. 37
Cargo Box ....................................................................... 37
Taillight Assembly............................................................ 38
Seats............................................................................... 38
Troubleshooting............................................................... 38

Engine/Transmission .................................................. 40

Troubleshooting............................................................... 41
Prowler XT/XTX (Table of Contents) ............................... 43
Prowler XTZ (Table of Contents)..................................... 88

Fuel/Lubrication/Cooling.......................................... 144

Electronic Fuel Injection (XT/XTX) ................................ 144
Electronic Fuel Injection (XTZ)...................................... 145
Gas Tank ....................................................................... 146
Gas/Vent Hoses ............................................................ 149
Oil Filter/Oil Pump......................................................... 149
Oil Cooler (XTZ) ............................................................ 150

Liquid Cooling System ...................................................151
Radiator .........................................................................151
Thermostat (XT/XTX) ....................................................152
Thermostat (XTZ) ..........................................................153
Fan.................................................................................153
Water Pump (XT/XTX)...................................................153
Water Pump (XTZ).........................................................154
Electric Fuel Pump/Fuel Level Sensor...........................155
Troubleshooting .............................................................157

Electrical System ...................................................... 158

Battery ...........................................................................158
RPM Limiter...................................................................159
Switches ........................................................................159
Accessory Receptacle/Connector .................................159
Brakelight Switch ...........................................................160
Engine Coolant Temperature (ECT) Sensor ..................160
Fan Motor ......................................................................160
Power Distribution Module (PDM)..................................161
Ignition Coil....................................................................162
EFI Sensors/Components .............................................162
Speed Sensor................................................................163
Electronic Power Steering (EPS) (XTZ).........................164
Electronic Power Steering (EPS) (XTX) ........................165
Ignition Switch ...............................................................167
Headlight Switch............................................................167
Drive Select Switch........................................................167
Reverse Override Switch ...............................................168
Front Drive Actuator.......................................................168
Stator Coil/Crankshaft Position (CKP) Sensor...............168
Starter Motor .................................................................169
Starter Relay..................................................................170
Electronic Control Unit (ECM) .......................................170
Regulator/Rectifier .........................................................171
Headlights......................................................................171
Taillight-Brakelight..........................................................171
Ignition Timing ...............................................................171
Tilt Sensor .....................................................................172
Throttle Position Sensor (TPS) ......................................173
ECM Error Codes (XT/XTZ) ..........................................174
EFI Diagnostic System (XTX) ........................................174
Troubleshooting .............................................................179

Drive System ............................................................. 181

Front Drive Actuator.......................................................181
Front Differential ............................................................182
Drive Axles ....................................................................194
Rear Gear Case ............................................................197
Hub ................................................................................200
Hydraulic Brake Caliper .................................................202
Universal Joints (XTZ) ...................................................205
Troubleshooting Drive System .......................................208
Troubleshooting Brake System ......................................208

Suspension................................................................ 209

Shock Absorbers ...........................................................209
Front A-Arms .................................................................210
Rear A-Arms..................................................................212
Wheels and Tires...........................................................213
Troubleshooting .............................................................214

Summary of Contents for PROWLER XT 2014

Page 1: ...PROWLER XT XTX XTZ ROV SERVICE MANUAL 2014 ...

Page 2: ...d decals display the words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to fol low the directive because it deals with the possibility of serious personal injury or even death A CAUTION identi fies unsafe practices which may result in vehicle related damage Follow the directive because it deals w...

Page 3: ......

Page 4: ...ble of Contents 88 Fuel Lubrication Cooling 144 Electronic Fuel Injection XT XTX 144 Electronic Fuel Injection XTZ 145 Gas Tank 146 Gas Vent Hoses 149 Oil Filter Oil Pump 149 Oil Cooler XTZ 150 Liquid Cooling System 151 Radiator 151 Thermostat XT XTX 152 Thermostat XTZ 153 Fan 153 Water Pump XT XTX 153 Water Pump XTZ 154 Electric Fuel Pump Fuel Level Sensor 155 Troubleshooting 157 Electrical Syste...

Page 5: ...learance cold engine max 0 1016 mm intake 0 1524 mm exhaust Valve Guide Stem Clearance max 0 013 mm Valve Guide Valve Stem Deflection wob ble method max 0 35 mm Valve Guide Inside Diameter 5 000 5 012 mm Valve Stem Outside Diameter 4 972 4 987 mm Valve Stem Runout max 0 1 mm Valve Head Thickness min 2 3 mm Valve Face Seat Width 2 25 mm intake 2 60 mm exhaust Valve Seat Angle 45 15 30 Valve Face Ra...

Page 6: ...be Arm Rest Steering Sup port 25 34 Rear ROPS Tube ROPS Support 35 48 Top ROPS Support Front Rear ROPS Tubes 35 48 Rear ROPS Tube Lower ROPS Support 35 48 Cargo Box Hinge Cargo Box Frame 20 27 Cargo Box Cargo Box Frame 20 27 Latch Pivot Bushing Cargo Box Frame 15 20 Latch Striker Cargo Box Liner 60 in lb 7 DRIVE TRAIN COMPONENTS Rear Gear Case Frame 38 48 Drive Coupler Front Drive Flange 40 54 Dri...

Page 7: ...nkcase 8 11 Secondary Drive Gear Nut Secondary Drive Output Shaft 74 100 Oil Filter Cover Crankcase 8 11 Shift Cam Stopper Crankcase 8 11 Shift Cam Stopper Spring Shift Cam Stopper 8 11 Shift Cam Plate Shift Cam Shaft 8 11 Shifter Housing Crankcase 8 11 Oil Strainer Cap Crankcase 8 11 Stator Coil Magneto Cover New 13 18 Stator Coil Magneto Cover Existing 11 15 ft lb N m ft lb N m ft lb N m ft lb N...

Page 8: ...y and correct fit Refer to the appropriate Illustrated Parts Manual for the correct part number quantity and description Preparation For Storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the vehicle thoroughly by washing dirt oil grass and other foreign matter from the entire vehi cle Allow it to dry thoroughly DO NOT get water into any part of the engin...

Page 9: ...miles and hours of trouble free riding 1 Clean the vehicle thoroughly 2 Clean the engine Remove the cloth from the exhaust system 3 Check all control wires and cables for signs of wear or fraying Replace if necessary 4 Change 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 7 Ch...

Page 10: ...ub Retaining Wrench 0444 270 Spanner Wrench 0444 240 Item Initial Service After Break In First Month or 100 Miles Every Day Every Month or Every 100 Miles Every 3 Months or Every 300 Miles Every 6 Months or Every 500 Miles Every Year or Every 1500 Miles As Needed Battery I I C Fuses I R Air Filter I I R Valve Tappet Clearance I I A Engine Compression I Spark Plug s I I I R 4000 Mi or 18 Mo Muffler...

Page 11: ...stall the center console and seats making sure the seats lock securely CHECKING AND CLEANING DRAINS 1 Inspect one way drains beneath the main housing for debris and for proper sealing 2 Replace any one way drain that is cracked or shows any signs of hardening or deterioration 3 Wipe any accumulation of oil or gas from the filter housing and one way drains Valve Tappet Clearance To check and adjust...

Page 12: ...n place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in Feeler Gauge Procedure sub section for the proper valve tappet clearance NOTE Rotating the valve adjuster dial counter clockwise will open the valve tappet clearance by 0 05 mm 0 002 in per mark E While holding the adjuster dial at the proper clear...

Page 13: ...30 ml 1 fl oz of oil into the spark plug hole s reattach the gauge and retest compression 8 If compression increases to normal service the pis ton rings see the appropriate Engine Transmission Top side Components Spark Plug s A light brown insulator indicates that the plug is correct A white or dark insulator indicates that the engine may need to be serviced To maintain a hot strong spark keep the...

Page 14: ...y excess oil after removing the filter 5 Apply oil to a new filter O ring and check to make sure it is positioned correctly then install the new oil filter Tighten securely 6 Install the engine drain plug and tighten to 16 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug 7 Start the engine while the vehicle is outside on level ground...

Page 15: ... tighten to 45 in lb 5 Pour the appropriate amount of recommended lubri cant into the fill hole 6 Install the fill plug NOTE If the lubricant is contaminated with water inspect the drain plug fill plug and or bladder Driveshaft Coupling The following drive system components should be inspected periodically to ensure proper operation A Spline lateral movement slop B Coupling cracked damaged or worn...

Page 16: ...an be adjusted vertically The geometric center of the HIGH beam light zone is to be used for vertical aiming 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 NOTE There should be an average operating load on the vehicle when adjusting the headlight aim 2 Measure the distance from the floor to the mid poin...

Page 17: ... C PR568A PR572A 4 Install the E clip then tighten the nuts A and B securely 5 Check each gear shift position for proper gear selec tion and make sure the proper icon illuminates on the LCD then install the center console and seats Shift Lever Shift Cable XTX CHECKING Turn the ignition switch on then shift the transmission into park The letter P should illuminate on the LCD gauge and the park icon...

Page 18: ...es ervoir is not above the MIN add DOT 4 brake fluid PR095 2 Depress the brake pedal several times to check for a firm brake If the brake is not firm the system must be bled 3 To bleed the brake system use the following proce dure A Remove the cover and fill the reservoir with DOT 4 Brake Fluid B Install and secure the cover then slowly depress the brake pedal several times C Remove the protective...

Page 19: ...iper holder to the knuckle with new patch lock cap screws Tighten to 20 ft lb PR377B E Install the wheel Tighten in a crisscross pattern in 20 ft lb increments to 80 ft lb aluminum wheels or 45 ft lb steel wheels 5 Burnish the brake pads see Burnishing Brake Pads in this section BRAKE DISC Using a micrometer measure the thickness of the brake disc in the contact surface If thickness is 0 125 in or...

Page 20: ...k Account for the washer UTV355 3 Remove the two cap screws securing the brake cali per to the rear drive housing and remove the caliper 4 Remove the anti rattle springs then push in on the caliper holder and remove the outer brake pad Remove the inner pad PR466A Inspecting and Measuring 1 Inspect the pads for gouges chips or wear 2 Inspect the disc for gouges grooves cracks and warpage 3 Using a ...

Page 21: ...rews securing the brake cali per to the gear case housing then remove the caliper assembly from the vehicle PR683A 4 Remove the two lock nuts A from the brake pad anchor bolts then remove the brake pads B Account for two springs and spacers C PR678A 5 Install the new brake pads and anchor bolts with springs and spacers then secure with new lock nuts PR679 6 Install the brake caliper onto the gear ...

Page 22: ...ition switch on Checking Replacing V Belt REMOVING 1 Remove the seats and center console then remove the left side seat base XT XTX or right side seat base XTZ 2 Remove the floor then on the XT XTX loosen the gas tank and slide it forward 3 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 gen...

Page 23: ...erclockwise until the V belt is flush with the top of the driven pulley 4 Place the V belt cover gasket into position then install the cover and secure with the cap screws mak ing sure the different lengthed cap screws are in their proper location Tighten the cap screws to 8 ft lb 5 Secure the seat base with the four cap screws Tighten securely 6 Slide the gas tank into position XT XTX and secure ...

Page 24: ...ehicle on a support stand to elevate the front wheels then 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 Make matching alignment marks on the pinion shaft and lower steering shaft joint PR333A NOTE Any time steering components are disas sembled all connecting components should be marked for...

Page 25: ... not repairable and must be replaced as an assembly however the tie rods and boots are replaceable REPLACING TIE RODS BOOTS 1 Secure the rack and pinion assembly in a vise or other suitable holding fixture then remove the tie rod end jam nut and rack boot 2 Slide the steering stopper A away from the inner tie rod end B then hold the rack C with a pipe wrench and remove the inner tie rod end from t...

Page 26: ...ighten the cap screw to 36 ft lb then check that the steering wheel turns freely 5 Install the tie rod ends into the steering knuckles then secure with the castle nuts coated with red Loc tite 271 tightened to 30 ft lb 6 Install the cotter pins and spread to secure 7 Install the wheels and tighten in a crisscross pattern in 20 ft lb increments to 80 ft lb aluminum wheels or 45 ft lb steel wheels C...

Page 27: ...emove the dash assem bly 6 Remove the four cap screws and nuts securing the steering shaft housing to the steering support then remove the cap screw securing the intermediate shaft yoke to the steering shaft PR764A PR765A 7 Remove the steering shaft housing and shaft from the steering support and intermediate shaft then remove the intermediate shaft from the EPS input shaft 8 Remove four cap screw...

Page 28: ...steering support 8 Secure the steering shaft housing to the frame with four cap screws and nuts Tighten the 6 mm nuts to 8 ft lb and the 8 mm nuts to 20 ft lb PR764B 9 Install the cap screw in the intermediate shaft coupler and tighten to 31 ft lb then tighten the cap screw from step 6 to 11 ft lb PR765A 10 Install the front storage box then install the dash and connect the two electrical connecto...

Page 29: ...ie rod joint to 37 ft lb using an appropriate crow foot PR781 NOTE Always attach the crow foot to the torque wrench with the open end 90 to the torque wrench handle to ensure accurate torque application 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 ...

Page 30: ...racket and secure with four cap screws Do not tighten the cap screws at this time PR773A 3 Place the tie rod ends into the knuckles and secure with the castle nuts coated with red Loctite 271 Tighten to 30 ft lb then install new cotter pins NOTE If the slots in the castle nut are not aligned with the hole in the tie rod end tighten until the cotter pin can be installed 4 Install the EPS assembly s...

Page 31: ...aft REMOVING 1 Remove the steering wheel 2 Remove the screws securing the dash panel to the frame PR181A 3 Slide the dash panel rearward to access the upper steering shaft joint then remove the cap screw secur ing the upper shaft joint to the steering wheel shaft PR313A 4 Match mark the upper steering shaft joint and the steering wheel shaft then remove the steering wheel shaft Account for the low...

Page 32: ...Tighten to 25 ft lb then install the hairpin clip NOTE If the hole in the steering shaft does not align with the slots in the castle nut tighten the nut slightly until the next slot aligns with the hole PR684A 6 Check for freedom of movement of the steering sys tem then install the steering wheel cover 7 Move the dash panel into position and secure to the frame and with the existing hardware PR181...

Page 33: ...on shaft does not protrude into the joint beyond the clamping surface Tighten to 36 ft lb PR309A 4 Install the upper steering shaft Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel 2 Remove the cotter pin from the axle 3 Remove the nut securing the hub 4 Remove the brake caliper 5 Remove the hub assembly 6 Remove the co...

Page 34: ...ss and driver press the bearing into the knuckle until firmly 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 end and secure with the nut coated with red Loctite 271 Tighten to 30 ft lb then install a new cotter pin and spread the pin NOTE During assembli...

Page 35: ...ements to 80 ft lb aluminum wheels or 45 ft lb steel wheels 10 Remove the vehicle from the support stand Checking Adjusting Front Wheel Alignment NOTE All measurements and adjustments must 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 f...

Page 36: ...cracking or bending INSTALLING Place the bumper assembly into position on the frame then secure with the four cap screws and nuts making sure the flat washers and lock washers are properly posi tioned Tighten to 35 ft lb Hood REMOVING 1 Open the hood then disconnect the four headlight connectors and remove two nylon ties PR328A 2 Loosen but do not remove the four cap screws and flange nuts securin...

Page 37: ...ts Tighten all four securely PR332 3 Connect the four headlight connectors then secure the wires with two new nylon ties PR332B Fenders REMOVING Remove three torx head screws securing each fender to the frame Account for a stiffener bracket on the front fenders PR311A INSTALLING Place the appropriate fender into position and secure with existing hardware Floor REMOVING 1 Remove the seats and cente...

Page 38: ... to the underside of the frame 2 Remove the belly panel INSTALLING 1 Place the belly panel into position on the underside of the frame 2 Install the body screws Tighten securely Accelerator Pedal REMOVING Dislodge the throttle cable holding grommet from the actuator arm then remove two torx head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator ...

Page 39: ...ecure with the flange nut Tighten securely 3 Install the jam nut and shift lever grip and tighten securely then check for proper shifter operation see Periodic Maintenance Shift Lever Shift Cable XTX LCD Gauge Indicator Lights REPLACING 1 Remove the six screws securing the dash panel to the frame then remove the parking brake handle and jam nut 2 Slide the dash panel to the rear sufficiently to ac...

Page 40: ...rews securing the pivot housings to the cargo box PR793A 3 Lower the cargo box then remove the four cap screws from step 2 4 With the help of an assistant or an adequate lift remove the cargo box from the vehicle Account for four pivot housings 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 weld...

Page 41: ...tion inadequate 3 Tire inflation pressure incorrect 4 Tie rod ends seizing 5 Linkage connections seizing 1 Adjust alignment 2 Lubricate appropriate components 3 Adjust pressure 4 Replace tie rod ends 5 Repair replace connections Problem Steering oscillation Condition Remedy 1 Tires inflated unequally 2 Wheel s wobbly 3 Wheel hub cap screw s loose missing 4 Wheel hub bearing worn damaged 5 Tie rod ...

Page 42: ...illation Condition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Parking brake adjusted incorrectly 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 1 Replace bearings 2 Replace tires 3 Replace rim 4 Tighten cap screws 5 Adjust parking brake 6 Replace bushing 7 Rep...

Page 43: ... first 10 hours or 200 miles are most critical to the life of this ATV Proper operation during this break in period will help assure maximum life and performance from the ATV Instruct the customer to follow the proper break in procedure as described in the Operators Manual SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this sectio...

Page 44: ...r coil 3 Replace ECM 4 Replace 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 w...

Page 45: ...erfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil change oil 2 Replace service rings cylinder 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 weak 3 Valve timing incorrect 4 Piston ring ...

Page 46: ...e vehicle on a suitable lift or jack stands allow ing room to perform work from the underside NOTE Locate the jack stands to allow removing of the center belly panel 1 Remove the seats and center console then remove the left side and right side seat bases 2 Remove the center belly panel then drain the oil and coolant NOTE Use a small funnel between the frame and coolant drain plug to prevent coola...

Page 47: ...R474B 6 On the XT remove the E clip from the transmission shift arm then disconnect the cable PR567A 7 On the XTX remove the cap screws securing the shift cable bracket to the engine case Remove the cap screw from the shift arm and disconnect the gear position switch connector Slide the gear position switch off the engine HDX251 8 Remove four machine screws securing the shifter mount to the frame ...

Page 48: ...frame then remove the air filter and mounting bracket as an assembly PR140A 11 Remove the throttle arm cover from the throttle body then disconnect and remove the throttle cable and the throttle body PR154A 12 Remove the coolant hoses from the water pump and thermostat housings then position the upper coolant line to the left side of the engine compartment PR150A 13 Remove the exhaust duct from th...

Page 49: ...t PR114 NOTE The front engine mounting bracket should slide free of the engine mounts first then the rear engine mounting bracket and two rear engine mounts will lift free of the frame PR146 Top Side Components NOTE For efficiency it is preferable to remove and dis assemble only those components which need to be addressed and to service only those components The technician should use discretion an...

Page 50: ... the 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 th...

Page 51: ... the cap screw securing the chain tensioner account for a washer then remove the tensioner FI617 10 Remove the five nuts securing the cylinder head to the cylinder CC017D CC018D 11 Remove the four cylinder head bolts NOTE On the 700 account for rubber O rings H1 016A 12 Remove the cylinder head from the cylinder remove the gasket and account for two alignment pins then remove the cam chain guide C...

Page 52: ...6D 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 service valves and cylinder head see Servicing Top Side Components sub section AT THIS POINT To inspect cam chain guide see Servicing T...

Page 53: ...ct 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 assem bly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Index all valves springs and cotters to their original position when removing When installing all valve compo...

Page 54: ...dial indicator on the surface plate then place the valve stem on a set of V blocks 2 Position the dial indicator contact point on the out side edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications Measuring Valve Guide Valve Stem Deflection Wobble Method 1 Mount a dial indicator and base on the surface plate then ...

Page 55: ... NOTE If the paint is not visible install the ends of the springs with the closest wound coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor compress the valve springs and install the valve cotters CC132D PISTON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Usi...

Page 56: ...ge measure each piston ring end gap Acceptable ring end gap must not exceed speci fications CC280D Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure the piston pin outside diameter at each end and in the center If measurement is not within speci fications the piston pin must be replaced ATV 1070 2 Insert an inside dial indicator into the piston pin bore The diameter must not exce...

Page 57: ...ng surface 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a heli coil insert 3 Place the cylinder head on the Surface Plate covered with 400 grit wet or dry sandpaper Using light pressure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any hi...

Page 58: ...the first measurements for a total of six measurements The trueness out of round ness is the difference between the highest and low est reading Maximum trueness out of roundness must not exceed specifications CC127D 2 Wash the cylinder in parts cleaning solvent 3 Inspect the cylinder for pitting scoring scuffing and corrosion If marks are found repair the surface using a 320 grit ball hone NOTE To...

Page 59: ...C005D 2 Place a strip of plasti gauge in each of the camshaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap screws Tighten securely NOTE Do not rotate the camshaft when measuring clearance 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve cover and cam shaft CC003D 5 Match the width of the plasti gau...

Page 60: ...lder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase CF083 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 remove the piston holder and seat the cylinder firmly on the crankcase CC024D ...

Page 61: ...ad nuts 10 Using a crisscross pattern tighten the four cap screws from step 8 initially to 20 ft lb then in 10 ft lb increments tighten to a final torque of 40 ft lb 11 Tighten the 8 mm nuts from step 9 to 21 ft lb and the 6 mm nuts to 8 5 ft lb then tighten the two cylin der to crankcase nuts from step 4 securely 12 With the timing inspection plug removed and the chain held tight rotate the crank...

Page 62: ...ylinder ensuring the following CF013A A Piston still at top dead center B Camshaft lobes directed down toward the pis ton 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 ...

Page 63: ... screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the ten sioner 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 fla...

Page 64: ...n starting from the center and working outward tighten the cap screws from step 29 to 8 5 ft lb 31 Adjust valve tappet clearance see Periodic Mainte nance 32 Place the two tappet covers into position making sure the proper cap screws are with the proper cover Tighten to 8 5 ft lb CC001D 33 If removed install the spark plug Tighten securely Right Side Components NOTE For efficiency it is preferable...

Page 65: ...t and remove the trig ger Account for the gasket NOTE It may be necessary to use a small two jaw puller to remove the trigger CD920 GZ254 5 Loosen the clamps securing the coolant hose to the water pump then remove the crossover tube from the cylinder head Account for an O ring 6 Remove the two cap screws securing the water pump to the engine then remove the water pump 7 Remove the cap screws secur...

Page 66: ...ter pump driven gear then remove the gear noting the direc tion of the sides of the gear for installing purposes Account for the driven gear alignment pin CD952A NOTE There is an oil passage beneath the driven gear drive gear assembly This passage should be plugged prior to removing the driven gear and drive gear Failure to do so could result in the loss of an alignment pin into the crankcase 14 R...

Page 67: ...se worn or discolored rollers If bearing is damaged it must be replaced FI569 3 Inspect the one way bearing for 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 Thoroughl...

Page 68: ...KSHAFT POSITION SENSOR 1 Remove the three cap screws 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 s...

Page 69: ...the water pump drive gear drive pin and the drive gear with the flat side of the gear facing out ward as noted in removing then secure with the snap ring CD946A CD944 NOTE The sharp side of the snap ring should be 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 with the beveled si...

Page 70: ...d Loctite 271 and tighten to 8 ft lb PR433A CD934 6 Install the shift cam stopper spring and two washers thick washer closest to the nut then coat the threads on the mounting stud with red Loctite 271 and install the nut Tighten to 8 ft lb PR434A NOTE Rotate the shift cam plate to ensure it ratch ets with no binding 7 Install the shift shaft with two washers making sure to align the timing mark on...

Page 71: ...s Tighten to 8 ft lb CD069 14 Place the water pump into position and secure with two cap screws Tighten to 8 ft lb NOTE Ensure the slotted water pump shaft is aligned with the groove in the counter balancer shaft 15 Install the crossover tube on the water pump and cylinder head making sure the O ring is properly positioned 16 On the XT install the shift arm on the shift arm shaft making sure the s...

Page 72: ...sher securing the movable drive face then remove the face Account for a spacer CD963 CD966A 3 Remove the V belt 4 Remove the bolt 550 or nut 700 securing the fixed driven assembly then remove the assembly H1 019 PR388 5 Remove the fixed drive face 6 Remove the cap screws securing the clutch cover Note the location of the different lengthed cap screws for installing purposes Using a rubber mallet c...

Page 73: ...ch 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 CF088A 9 On the XT remove the two cap screws securing the gear position switch then remove the switch Account for two contact pins with springs CD997 10 Remove the nut left hand threads securing the clutch sho...

Page 74: ... 13 Remove the snap ring securing the oil pump driven gear A 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 14 Using an impact driver remove the three torx head screws securing the oil pump then remove the pump CD988 Servicing Left Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoes fo...

Page 75: ...mp 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 DRIVEN PULLEY ASSEMBLY NOTE The driven pulley is a non serviceable com ponent If the pulley faces cam ramps or sheave bushing are worn or loose the pulley must be replaced as an assembly Do not disassemble the driven pulley Installing Left Side Components 1 On the XT...

Page 76: ...ase Tighten the oil pump screws to 8 ft lb Install the washer and pin 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 with each other 6 Install the clutch shoe assembly and secure with the flange nut threads coated with red Loctite 271 Ti...

Page 77: ...s are in their proper location Tighten to 8 ft lb H1 023 12 Place the driven pulley assembly into position and secure with the bolt 550 or nut 700 Tighten to 80 ft lb 550 or 162 ft lb 700 CF262 13 Tighten the cap screw with washer to 60 ft lb H1 019 14 Slide the fixed drive face onto the clutch shaft 15 Spread the faces of the driven pulley by threading a cap screw into one of the bosses of the dr...

Page 78: ...until the V belt is flush with the top of the driven pulley 19 Place the V belt cover gasket into position then install the cover and secure with the cap screws making sure the different lengthed cap screws are in their proper loca tion Tighten the cap screws to 8 ft lb CD083 Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Complete Removing ...

Page 79: ...n installing it is recommended that the assemblies are kept together and IN ORDER PR787A 1 Remove the secondary driven shaft assembly A noting the location of the bearing locating pins Account for the bearing C ring PR787B 2 Remove the reverse idler gear assembly F Account for all washers shaft bushing and the gear CC668 3 Remove the shift shaft H then remove the two forks taking note of the direc...

Page 80: ...t assem bly NOTE Use a protective end cap to prevent damage to the crankshaft threads 11 Remove the cap screws securing the oil strainer cap then remove the cap 12 Remove the two cap screws securing the oil strainer then remove the strainer NOTE Thoroughly clean any sealant from the oil strainer cap PR406 13 To remove the secondary drive bevel gear remove the secondary drive bearing housing then r...

Page 81: ...aft until the gear firmly seats on the shoulder of the shaft MT011B 3 If installing the existing shaft start with the shims removed during disassembly or if installing a new shaft start with approximately 1 0 mm shims at point D then install the output drive shaft bearing E making sure the locating pin is directed toward the center of the shaft MT012 MT008A 4 Install a new seal F output yoke G and...

Page 82: ...ten the output shaft nut to 59 ft lb and the output yoke nut to 74 ft lb CRANKSHAFT ASSEMBLY NOTE The crankshaft and connecting rod is a non serviceable assembly If any component is out of specification the assembly must be replaced Measuring Connecting Rod Small End Inside Diameter 1 Insert a snap gauge into the upper connecting rod small end bore then remove the gauge and measure it with microme...

Page 83: ...bling 1 Remove the shift forks noting the positions for assem bling then remove the high driven gear outer washer high driven gear high driven gear bearing high driven gear bushing and high driven gear inner washer GZ283A 2 Remove the drive gear then remove the snap ring secur ing the reverse driven gear dog and bushing to the coun tershaft GZ296 GZ312 3 Remove the reverse driven gear dog CAUTION ...

Page 84: ...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 washer GZ316 Assembling 1 From the drive gear end install a thrust washer bushing and bearing then install the low driven gear and washer GZ317A GZ318 ...

Page 85: ...ar GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap ring GZ288A GZ314 5 Install the reverse driven gear dog onto the counter shaft and secure with a snap ring GZ313A GZ312 6 From the opposite end of the countershaft install the high low driven gear dog A thrust washer B bushing C bearing D high low driven gear E and spacer washer F ...

Page 86: ...moke then slide the crankshaft assembly into place CC688 CC689 NOTE If heating the bearing is not possible the crank shaft can be installed using a crankshaft installing tool 3 Install the crank balancer CD832B NOTE It will be necessary to rotate the crank balancer until the counterweight is facing away from the crank shaft then rotate the crankshaft clockwise into the jour nal area to allow the c...

Page 87: ...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 assem blies 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 oil...

Page 88: ...nd 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 Attach suitable lifting chains to the engine transmission then using an engine hoist lower the assembly into the engine compartment PR114 NOTE The rear engine mounting bracket and rear engine mounts should be attached to th...

Page 89: ...exhaust duct connecting the outlet housing to the V belt housing Tighten all clamps securely HDX140A PR144B 7 Connect the lower coolant hose to the water pump housing then connect the upper coolant hose to the thermostat housing Tighten the hose clamps securely 8 Install the starter wire on the starter and tighten the nut securely then connect the alternator connector and gear position switch conn...

Page 90: ...cable bracket to the engine case and tighten the engine case screws to 8 ft lb Connect the gear position switch connector HDX252A 15 Fill the engine transmission with the appropriate lubri cant 16 Remove the coolant bleed screw from the upper coolant pipe near the thermostat then pour the correct mixture of coolant into the radiator When coolant with no air bub bles flows from the bleed hole insta...

Page 91: ... the vehicle on a suitable lift or jack stands allow ing room to perform work from the underside NOTE Locate the jack stands to allow removing of the center belly panel 1 Remove the seats and center console then remove the left side and right side seat bases 2 Remove the storage console then remove the floor and drain the oil into a suitable container PR611 3 Clamp off the lower radiator hose near...

Page 92: ...ector E PR594A 8 Remove the rear spark plug cap then from the left side remove the fuel injector connector A mani fold absolute pressure MAP sensor B parking brake warning switch C reverse override switch connector D and idle speed control ISC valve E PR595A 9 Disconnect the front ignition coil and remove the front spark plug then route the engine harness out of the engine compartment PR596 10 Fro...

Page 93: ...OTE The parking brake cable does not need to be disconnected 14 Using a shop towel to absorb any spilled gasoline remove the quick disconnect fuel couplers from the fuel injectors PR663A 15 Remove four sheet metal screws securing the air fil ter mounting bracket to the frame then loosen the intake boot clamp and remove the air filter assembly CAUTION The gear position switch wires are secured to t...

Page 94: ...stat housing then move the coolant pipe to the left side of the vehicle PR607A 19 Remove the sheet metal screws securing the constant variable transmission CVT cooling duct to the frame then loosen the hose clamps and remove the duct from the front elbow and CVT boot PR671A 20 Remove the inlet boot from the CVT cover then remove the outlet boot from the rear of the CVT cover PR670A 21 Remove the o...

Page 95: ...ust pipe to the cylinder head then remove two springs securing the front and rear exhaust pipes together Remove the front exhaust pipe Account for a grafoil seal and a grafoil gasket PR643A PR661A PR625A NOTE The grafoil gasket may remain in the cylinder head 24 Remove the cap screws securing the rear exhaust pipe to the cylinder head and remove the exhaust pipe Account for a grafoil gasket ...

Page 96: ...utput yoke PR638A PR639A 26 Remove four cap screws securing the rear driveshaft to the output flange The rear driveshaft can remain on the vehicle PR647 27 Remove the lock nuts from the engine through bolts then attach a lifting chain to the engine transmission PR630 PR629 PR631 28 Using a suitable engine hoist remove the weight from the through bolts then remove the bolts Account for a flat washe...

Page 97: ...Cylinder Head Camshaft 1 Remove the timing inspection plug spark plugs and magneto housing cover then install the 10 mm cap screw left hand threads in the crankshaft and rotate the desired cylinder to top dead center of the compression stroke GZ027 GZ026 NOTE Timing marks on the rotor flywheel are stamped with an F front cylinder and R rear cyl inder adjacent to the mark GZ063 GZ059 2 Remove the t...

Page 98: ... the tensioner clockwise to remove the tension Remove the two cap screws securing the tensioner adjuster assembly and remove the assembly Account for a gasket GZ405 7 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken not to drop the C ring into the crankcase GZ155 8 Bend the washer tabs down and remove the two cap scr...

Page 99: ... guide GZ151 GZ161 12 If the remaining cylinder head is to be serviced apply tension to the loose timing chain and rotate the second cylinder to top dead center of the compression stroke then repeat steps 2 11 on the other cylinder head C Cylinders D Pistons NOTE Steps 1 12 in the preceding sub section must precede this procedure 13 Remove the cap screws securing the water hose union to the cylind...

Page 100: ...r NOTE Support the connecting rod with rubber bands or a piece of hose to avoid damaging the rod or install a suitable connecting rod holder GZ146A AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub section CAUTION When removing the cylinder be sure to support the pis ton to prevent damage to the crankcase and piston CAUTION Do not allow the connecting rod to go down inside t...

Page 101: ...ir 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 CC136D NOTE The valve seals must be replaced 3 Remove the valve ...

Page 102: ...ing Valve Guide Inside Diameter 1 Insert a suitable bore gauge 1 2 way into each valve guide bore and record the measurement 2 Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance it must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replacement Arctic Cat recommends the components b...

Page 103: ...g as a tool clean carbon from the ring grooves Be sure to position the ring with its tapered side up 3 Using a non metallic carbon removal tool remove any carbon buildup from the dome of the piston 4 Inspect the piston for cracks in the piston pin dome and skirt areas 5 Inspect the piston for seizure marks or scuffing 6 Inspect the perimeter of each piston for signs of excessive blowby Excessive b...

Page 104: ...ract this measurement from the measurement in step 1 The difference clearance must not exceed specifications Installing Piston Rings 1 Install the expander spring making sure the ends are aligned on the wire then install the oil ring with the ring gap 90 from the spring gap and the marking E TOP directed toward the top of the piston GZ168 GZ169A 2 Install the second compression ring with the marki...

Page 105: ... are found repair the surface using a cylinder hone see Inspecting Cylinder 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...

Page 106: ...te the camshaft and note runout maximum run out 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 Inspect the bearing journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylind...

Page 107: ... be replaced Installing Top Side Components A Pistons B Cylinders 1 Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston NOTE The piston should be installed so the arrow points toward the exhaust of the respective cylinder GZ166 2 Place the two alignment pins into position Place the cyl inder gasket into position with a drop of silicone sealan...

Page 108: ...t hose onto the crankcase union and tighten the clamp C Cylinder Head D Valve Cover NOTE Steps 1 5 in the preceding sub section must precede this procedure 6 Place the chain guide into the cylinder GZ161A 7 Place a new head gasket into position on the cylin der Place the alignment pins into position then place the head assembly into position on the cylinder while guiding the cam chain through the ...

Page 109: ...n the front cam shaft loosely place the cam sprocket with the recessed side facing the cam shaft lobes onto the camshaft At this point do not seat the sprocket onto the shaft 732 307B GZ130 NOTE At this point oil the camshaft bearings cam lobes and the three seating journals on the cylinder 13 With the cam lobes directed down toward the pis ton maneuver the camshaft sprocket assembly through the c...

Page 110: ...install the cap screw threads coated with red Loctite 271 and tighten to 11 ft lb Bend the tab to secure the cap screw GZ193 18 Rotate the crankshaft until the first cap screw from step 16 can be tightened then tighten to 11 ft lb Bend the tab to secure the cap screw 19 Keeping tension on the rear cam chain rotate the engine forward 270 until rear piston is at TDC indi cated by timing mark R CAUTI...

Page 111: ...ead If rotating the cam shaft is necessary for alignment rotate the sprocket inside the chain until the alignment pin can be engaged in the sprocket with the camshaft in the nearest possible position to parallel GZ519 GZ518 22 Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket then place the cam shaft sprocket assembl...

Page 112: ...11 ft lb Bend the tab to secure the cap screw GZ193 CD465 26 Rotate the crankshaft until the first cap screw from step 23 can be addressed then tighten to 11 ft lb Bend the tab to secure the cap screw GZ194 27 Place the C rings into position in their grooves in the cylinder heads CC012D 28 Install the cylinder head plugs in the cylinder heads with the open end facing downward and toward the inside...

Page 113: ...et into position on the cylinder and secure with the two cap screws CD469 31 Using a flat blade screwdriver rotate the adjuster screw inside the tensioner counterclockwise until the tensioner spring bears tension then install the cap screw into the end of the chain tensioner GZ201 CD471 32 Loosen the four adjuster screw jam nuts then loosen the four adjuster screws on the rocker arms in the valve ...

Page 114: ...ed 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 Left Side Components A Magneto Cover Stator Coils B Water Pump C Shifter Assembly D Rotor Flywheel Starter Clutch E Speed Sensor Trigger Assembly 1 Remove the cap screws securing the magne...

Page 115: ...4 Install Magneto Rotor Remover Set and loosen the rotor flywheel then remove the crankshaft protector and rotor flywheel from the crankshaft Account for the flywheel key GZ216 GZ217 5 With the flywheel key removed remove the starter ring gear and spacer washer GZ226 GZ249 6 Remove the hose clamps from the water pump then remove the coolant hoses from the water pump out lets and coolant pipes GZ21...

Page 116: ... securing the shift cam plate to the shift cam shaft and remove the shift cam plate then remove the shift shaft H2 022A 12 Remove the snap ring securing the speed sensor trig ger to the shaft and remove the trigger using a suit able two jawed puller Account for a gasket H2 023 13 Remove the cap screws securing the oil filler cover to the crankcase then remove the cover Account for an O ring GZ250 ...

Page 117: ...wheel FI570 2 Thoroughly clean the rotor flywheel then install the new starter one way clutch and secure with the cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a crisscross pat tern 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 ...

Page 118: ... screws using a drop of red Loctite 271 on each If installing the existing magneto cover tighten the cap screws to 11 ft lb If installing a new mag neto cover tighten the cap screws 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 with the c...

Page 119: ...hift cam stopper spring onto the shift cam stopper and secure with a flat washer and nut Tighten to 8 ft lb H2 019 6 Install the shift cam plate onto the shift cam shaft and secure with the cap screw Tighten to 8 ft lb H2 022A 7 Install the shift shaft into the crankcase making sure the washer is properly located then align the timing reference marks and completely seat the shift shaft FW 019 H2 0...

Page 120: ... oil from the crankshaft surface and rotor fly wheel bore and install the rotor flywheel onto the crankshaft aligning the keyway with the key Secure with the nut coated with red Loctite 271 tightened to 105 ft lb GZ225 13 Install the starter driven and counter gear shafts D into the crankcase longer shaft to the front then install the starter countershaft gear C starter driven gear A and bushing B...

Page 121: ...s not have to be removed from the frame for this procedure Removing Right Side Components A CVT Cover B Driven Clutch C Clutch Cover D Centrifugal Clutch 1 Remove the cap screws securing the CVT cover then using a rubber mallet gently tap on the cover tabs to loosen the cover Account for a gasket and two alignment pins GZ244B 2 Remove the nut securing the movable drive face then remove the face Ac...

Page 122: ...e clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pins GZ246B 8 Using a suitable press remove the clutch housing from clutch cover account for fixed drive face spacer and O ring GZ511 CC596 NOTE Account for and inspect the clutch housing seal 9 Remove the two cap screws securing the gear posi tion switch then remove the switch Account for two contact pi...

Page 123: ...lutch Note the location of the green dot or the word OUTSIDE for installing purposes 14 Remove the nut left hand threads securing the clutch shoe assembly GZ438A NOTE Heating the nut will aid in removal 15 Remove the two cap screws securing the gear posi tion switch then remove the switch 16 Remove the water pump drive housings Account for a gasket and two locator pins GZ437A 17 Remove the water p...

Page 124: ...nap rings from the driveshaft then remove the gear and drive pin noting the orientation of the gear for proper assembly GZ442 2 Remove the snap ring securing the bearing in the water pump drive cover then remove the bearing using an appropriate blind bearing remover GZ441 Inspecting 1 Inspect the water pump drive housing A for scoring or discoloration GZ440A 2 Inspect the bearing B for smooth rota...

Page 125: ...e with the flange nut threads coated with red Loctite 271 Tighten to 221 ft lb GZ241 3 Install the one way clutch onto the clutch shoe assembly GZ247B 4 Place a new clutch housing seal with the spring side facing the clutch housing seal tool into the clutch cover and secure with a rubber mallet or press GZ503 5 Using a suitable press install the bearing into the clutch cover against the outer bear...

Page 126: ...12 8 Install a new O ring into a new fixed drive spacer then apply a thin coat of grease to the inner O ring and outside sealing surface of the drive spacer Place it over the clutch housing assembly ATV2109 9 Place the clutch cover clutch housing assembly into position on the crankcase then secure with the cap screws Tighten in a crisscross pattern to 8 ft lb GZ246B 10 Making sure the alignment pi...

Page 127: ...re the drive face with a flat washer and a nut threads coated with red Loctite 271 Tighten the nut to 165 ft lb GZ075 GZ485 NOTE At this point the cap screw can be removed from between the driven clutch faces 16 With the engine in neutral rotate the V belt and clutches counterclockwise until the V belt is flush with the top of the driven clutch 17 Place the CVT cover gasket into position then inst...

Page 128: ...d and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the oil strainer cap then remove the oil strainer H2 012A GZ446 2 Remove the cap screws securing the lower crankcase to the upper crankcase halves then using a rubber hammer free the lower crankcase and remove Account for two alignment pins H2 012B 3 Remove the second...

Page 129: ...he location of two alignment pins GZ454A GZ272B Disassembling Crankcase Half NOTE For steps 1 8 refer to illustration GZ474A GZ474A NOTE To aid in installing it is recommended the assemblies are kept together and IN ORDER 1 Support the right side crankcase assembly on suit able support blocks then carefully remove the crank shaft assembly A from the crankcase GZ298 2 Remove the snap ring securing ...

Page 130: ...OTE Do not disassemble the countershaft assem bly unless necessary If necessary see Servicing Center Crankcase Components sub section Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set Up NOTE If the secondary output driven shaft is replaced or disassembled the initial set up must be performed to establish correct gear tooth contact If only the secondary output drivesha...

Page 131: ...and nut H and tighten to 200 ft lb MT008B NOTE Do not use a new lock nut at this time as this procedure may have to be repeated 5 Place the assembled shaft into the left crankshaft case then lightly coat the gear teeth with 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...

Page 132: ...o remove measure and install until backlash measurement is within tolerance Note the following chart 3 Once correct gear pattern and backlash are estab lished install a new lock nut coated with red Loctite 271 on the output yoke and tighten to 200 ft lb Peen the lock nut to the shaft MT007A 4 Using an appropriate holding fixture and wrench adapter install the secondary drive gear nut threads coate...

Page 133: ...shaft and drive pin for exces sive wear or grooving Replace as required GZ354A 6 Remove the oil seal from the oil pump cover GZ365 Assembling 1 Install a new oil seal into the oil pump cover then coat the lips of the seal with grease and install the pump driveshaft from the seal side GZ359 2 Noting the reference dots on the gerotor set separate the inner rotor from the outer rotor and with the ref...

Page 134: ...tions 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 Zero the indicator and push the small end of the con necting rod away from the dial indicator 3 Maximum deflection must not exceed specifications Mea...

Page 135: ...assembling then remove the high driven gear outer washer high driven gear high driven gear bearing high driven gear bushing and high driven gear inner washer GZ283A 2 Remove the drive gear then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft GZ296 GZ312 3 Remove the reverse driven gear dog CAUTION Care should be taken to support the connecting rod when rot...

Page 136: ...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 washer GZ316 Assembling 1 From the drive gear end install a thrust washer bushing and bearing then install the low driven gear and washer GZ317A GZ318 ...

Page 137: ...ear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap ring GZ288A GZ314 5 Install the reverse driven gear dog onto the counter shaft and secure with a snap ring GZ313A GZ312 6 From the opposite end of the countershaft install the high low driven gear dog A thrust washer B bushing C bearing D high low driven gear E and spacer washer F ...

Page 138: ...at side away from the gear GZ347 3 Install the countershaft into the crankcase and secure with the snap ring flat side away from the bearing GZ463A 4 Install the countershaft gear onto the countershaft and secure with a snap ring flat side away from the gear GZ299A 5 Using rubber bands to support the connecting rods carefully install the crankshaft assembly into the crankcase GZ474 NOTE It will be...

Page 139: ...shift forks and shift fork shaft install the countershaft assembly into the crankcase GZ280B GZ336 9 Engage the shift forks into the gear shift shaft and push the shift fork shaft into the crankcase GZ339 AT THIS POINT Proper transmission shifting should be verified by turn ing the gear shift shaft to select High Low Neutral and Reverse while rotating the input shaft and observing the countershaft...

Page 140: ...ght side Secure with the cap screws eight left side and one right side GZ342 5 Tighten the 6 mm cap screws to 10 ft lb and the 8 mm cap screws to 21 ft lb using the pattern shown and turning the shafts frequently to ensure there is no binding NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs GZ457A NOTE Cap screw number eight 8 is installed from the right side NOTE If t...

Page 141: ...and the 8 mm cap screws to 21 ft lb GZ447 10 Install the oil strainer then apply a thin bead of silicone sealant to the oil strainer cap and secure with the cap screws Tighten to 8 ft lb Installing Engine Transmission NOTE Arctic Cat recommends new gaskets and O rings be installed whenever servicing the vehicle 1 Attach a suitable lifting chain to the engine then using an engine hoist lift the eng...

Page 142: ...nd tighten to 40 ft lb PR629 PR630 4 Secure the rear universal joint flange to the output drive flange and tighten the four cap screws to 40 ft lb PR647 5 Lubricate the splines on the front driveshaft with multi purpose grease then align the match marks and install the driveshaft into the front output joint PR639 6 Align the match mark on the front drive flange to mark on the front universal joint...

Page 143: ... pipe and loosely secure with two cap screws PR643A PR642 9 Install the O2 sensor and tighten the sensor to 19 ft lb Connect the harness to the sensor 10 Install the two springs A at the juncture of front and rear exhaust pipes With a new grafoil seal B in place install the muffler and secure with two springs then tighten the cap screws from steps 7 and 8 to 20 ft lb PR661C PR668 11 Connect the oi...

Page 144: ...rient the outlet duct PR669 14 Connect the starter cable to the starter then connect the engine harness ground to the engine Tighten the fasten ers securely PR605A PR604A 15 Install the air filter assembly and secure with four sheet metal screws then secure the intake boot to the throttle body Tighten the screws and clamp to 30 in lb PR603A 16 Connect the gasline hoses to the fuel rails making sur...

Page 145: ...ts securely 19 Adjust throttle cable free play then install the throt tle cable cover PR666 20 Install the shift cable support bracket and secure with two cap screws then tighten to 8 ft lb and install the E clip securing the shift cable to the shift arm PR662A 21 From the left side connect the speed sensor connec tor F stator coil connector G CKP sensor H and gear position switch connector I PR65...

Page 146: ...rrect routing of all wiring hoses and cables PR592A 26 Connect the negative battery cable and install the battery hold down 27 Pour the recommended amount of oil into the engine transmission 28 Remove the coolant bleed screw from the upper coolant pipe near the thermostat then pour the cor rect mixture of coolant into the radiator When cool ant with no air bubbles flows from the bleed hole install...

Page 147: ...n Clean or replace as necessary see the Peri odic Maintenance section REMOVING THROTTLE BODY 1 Turn the ignition switch to the OFF position then remove the ignition switch key 2 Remove the left and right seats then remove the cen ter console and disconnect the battery 3 Remove the connector from the IAT sensor A then loosen the inlet boot clamp B and remove the mounting screw C PR486A 4 Disconnect...

Page 148: ...nd can be heard see Electric Fuel Pump Fuel Level Sensor in this section 2 Check for a flashing EFI icon on the LCD If EFI is flashing see ECM Error Codes in the Electrical Sys tem section 3 Make sure there is sufficient clean gas in the gas tank 4 Verify that the battery is sufficiently charged to crank the engine over at normal speed 5 Check the air filter housing and air filter for contam inati...

Page 149: ...d and secure with the cap screws Tighten securely GZ386 3 Connect the TPS connector A MAP sensor con nector B and ISC connector C to the throttle body then install the air inlet boot and tighten the clamps securely GZ094E 4 Install the center console and seats making sure the seats lock securely in place Gas Tank REMOVING 1 Remove the seats and center console then remove the left side and right si...

Page 150: ...vel sensor connector C then cap the vent fitting and gas hose fitting PR698A 6 Remove the outer cap screw securing the front tank hold down then swing the hold down to the left PR167A PR170 7 Remove four press nuts securing the gas cap inset then remove the gas cap and inset Install the gas cap PR168 8 Remove the joining cap screw and nut from the rear gas tank hold down strap then remove the insi...

Page 151: ...1 Place the gas tank into position in the vehicle then install the inside rear hold down strap PR173 PR699A 2 Swing the front hold down to the right into position and install the cap screw and nut Do not tighten at this time PR171 3 Install the rear hold down strap joining cap screw and nut Do not tighten at this time PR699A 4 Place the gas cap filler panel into position then if necessary position...

Page 152: ...ase of the oil filter then using an appropriate adapter connect an oil pressure gauge to the engine CF264A NOTE Some oil seepage may occur when installing the oil pressure gauge Wipe up oil residue with a cloth 4 Set the parking brake and start the engine Allow the engine to warm up to operating temperature with cooling fan cycling 5 Set the speedometer tachometer to RPM With the engine running at...

Page 153: ...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 4 Inspect the pump housing and cover for cracks or damage ASSEMBLING INSTALLING 1 Place the rotors into the pump housing making sure the alignment pin is in the groove of the rotor 2 Place the...

Page 154: ... A securing the under hood storage box to the frame then remove two cap screws with nuts B at the front of the stor age box PR182A 3 While lifting up on the front of the storage box pry the rear center clear of the center dash mount and remove the storage box PR186 4 Drain the coolant into a suitable container then dis connect the cooling fan wire connector from the main harness PR183A 5 Remove th...

Page 155: ...and pipe in the radiator neck Add coolant as necessary Thermostat XT XTX 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 Account for a thermo stat with seal INSPECTING 1 Inspect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the thermo stat for pr...

Page 156: ... open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear NOTE All coolant hoses and clamps should be replaced every four years or 4000 miles INSTALLING 1 Place the thermostat and O ring into the thermostat housing then secure the thermostat housing together with the four machine screws 2 Fill the cooling system with the recommended amount of an...

Page 157: ...Fill the engine transmission with the proper amount of recommended oil 4 Fill the cooling system with the proper amount of recommended coolant NOTE While the cooling system is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engine off and then fill the cooling system 5 Check the entire cooling system for leakage 6 Install the right sid...

Page 158: ...or The electric fuel pump and fuel level sensor are not ser viceable components If either component fails it must be replaced TESTING 1 Turn the ignition switch ON and listen for a momen tary whirring sound of the pump building pressure If the sound is heard 10 seconds no electrical checks are necessary Turn the ignition switch OFF 2 Disconnect the gasline hose from the fuel rail then install a su...

Page 159: ...ATV2116 NOTE If readings are erratic clean the resistor wiper and resistor with clean alcohol and retest If still not correct replace the fuel level sensor 4 To replace the fuel level sensor use the following procedure A Disconnect the two wire connector A then press the fuel level sensor toward the top of the fuel pump to release it from the mounting slot B FI460A B Engage the tabs C of the fuel ...

Page 160: ...1 Gas contaminated 1 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 TPS out of adjustment 1 Adjust TPS Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 1 Decrease RPM speed ...

Page 161: ...ort engine run times Frequent winch usage snowplowing extended low RPM operation short trips and high amperage accessory usage are also reasons for battery discharge Maintenance Charging NOTE Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging Maintenance charging is required on all batteries not used for more than two weeks or as requi...

Page 162: ...arge 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 operator expectations bring...

Page 163: ...essed the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance replace the switch Engine Coolant Temperature ECT Sensor 1 Connect the meter leads selector in OHMS position to the sensor terminals 2 Suspend the sensor and a thermometer in a container of cooking oil then heat the oil NOTE Neither the sensor nor the thermometer should be allowed to touch the bottom o...

Page 164: ...ly one side of the fuse holder connector terminal the other side will show no voltage NOTE When testing the HI fuse holder the head light OFF HI LO switch must be in the HI position when testing the LIGHTS fuse holder the headlight dimmer switch can be in either the HI or LO position NOTE If the meter shows no battery voltage trou bleshoot the battery switches power distribution module or the main...

Page 165: ...the meter does not show as specified replace the spark plug cap VOLTAGE Primary Coil 1 Set the meter selector to the DC Voltage position then disconnect the two wires from the coil NOTE The coil is located to the right of the engine and may be accessed from behind the right side seat with the cargo box raised 2 Connect the red tester lead to the orange wire and the black tester lead to the blue wh...

Page 166: ...he black pink wire and the red tester lead to the orange blue wire The meter should read 4 5 5 5 DC volts If the meter does not read as specified check the ECM connector or wiring 4 Connect the MAP IAT to the harness then using MaxiClips connect the red tester lead to the brown white wire and the black tester lead to the black pink wire With the engine running at idle speed the meter should read a...

Page 167: ... EPS assembly and therefore can be cleared without replacement of the EPS assembly Make sure to thoroughly troubleshoot the entire system before replacing the EPS assembly NOTE The EPS assembly is not serviceable and no service parts or parts lists are available The EPS is only serviceable as an assembly and must not be dis assembled or EPS warranty will be voided Malfunction code P0635 will appea...

Page 168: ...ing shaft to assist the driver when rotating the steering wheel Driver steering inputs are detected by a torque sensing transducer assembly within the EPS housing These inputs are converted to electronic signals by the transducer and control circuitry to tell the motor which way to drive the steering shaft When no steering input pressure on the steer ing wheel is detected no torque signal is gener...

Page 169: ...e EPS has lost CAN communica tion with the EFI ECM Broken CAN wires in the main harness EFI ECM connector has been discon nected Correct EPS condition C1318 Internal CRC Error EPS internal CRC calculation condi tion has been detected EPS reflash has failed Battery power was lost or the keyswitch was turned off during EPS reflash programming EPS must be reprogrammed C1319 Boot Counter Exceeded EPS ...

Page 170: ... to the black wire 2 Turn the ignition switch to the ON position The meter must show battery voltage NOTE If the meter does not show battery voltage troubleshoot the LIGHTS fuse on the power distribu tion module the ignition switch or the main harness 3 Connect the red meter lead to the yellow wire then select the high beam position on the headlight switch The meter must show battery voltage 4 Con...

Page 171: ...h 30 amp fuse and wiring connections prior to testing the actuator NOTE The differential must be in the unlocked position for this procedure VOLTAGE 1 Locate the 4 wire connector for the front drive selector actuator on the frame to the right of the differential then connect the red meter lead to the orange wire using a MaxiClip PR293 2 Connect the black lead to the black wire using a Maxi Clip th...

Page 172: ...OLTAGE NOTE The battery must be at full charge for these tests Crankshaft Position Sensor 1 Set the meter selector to the AC Voltage position 2 Connect the red tester lead to the blue wire XT XTZ or brown wire XTX then connect the black tester lead to the green wire XT XTZ or white wire XTX 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Starter ...

Page 173: ...rake set 3 Depress the starter button while observing the multi meter The multimeter should drop to 0 volts and a click should be heard from the relay NOTE If a click is heard and more than one volt is indicated by the multimeter replace the starter relay If no click is heard and the multimeter continues to indicate battery voltage proceed to step 4 4 Disconnect the two wire plug from the starter ...

Page 174: ...dule headlight switch ignition switch switch con nectors or wiring harness Taillight Brakelight VOLTAGE Taillight NOTE Perform this test at the socket end of the tail light brakelight harness pigtail The ignition switch must be in the ON position and either high beam or low beam selected on the light switch 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the ...

Page 175: ...NOTE Needle adapters will be required on the mul timeter leads as the following tests are made with the sensor connected 1 Connect the three wire plug to the sensor then remove the right side mounting screw securing the sensor to the rear frame CD707 2 Install the needle adapters to the multimeter leads then select DC Voltage on the multimeter 3 Connect the red tester lead to the blue brown wire B...

Page 176: ... be adjusted 2 Connect the TPS Multi Analyzer Harness connector 8 to the TPS then connect the harness to the TPS Analyzer Tool FI672 3 Using a multimeter connect the black tester lead to the white socket VAR on the analyzer and the red tester lead to the red socket 5V then select the DC Voltage position With the vehicle off the gauge should read 0 58 0 62 and at Wide Open Throttle it should read u...

Page 177: ...95 Sensor Power 96 Incorrect ECM 97 ECM Memory Power constant battery power 98 ECM to Gauge Comm Link H2 99 Start Run Not Possible active code only Will initiate code 99 After all stored codes are cleared clear the error code s using the following procedure NOTE The ignition switch should be in the OFF position 1 With the test plug connected to the diagnostic plug and the drive select switch in th...

Page 178: ...c Mode EFI 003 Display Engine coolant temperature as measured by the ECT sensor DTC P0116 P0117 P0118 P0119 Usage Monitor coolant temperature to verify the following 1 ECT sensor signal 2 High Temperature indicator on 230 F 3 Thermostat opening approximately 180 F indi cated by a momentary drop or pause in the rising temperature reading 4 Fan ON 185 F OFF 175 F A fan motor B fan relay C fan fuse D...

Page 179: ...ECM CAN signal to EPS unit TPS tPS Diagnostic Mode EFI007 Display of TPS 0 closed 95 100 WOT DTC P0121 P0122 P0123 Usage Verify TPS signal and adjust throttle cable MAP bArO Diagnostic Mode EFI006 Display MAP in millibars 1013 millibar 29 92 in mercury DTC P0107 P0108 Usage Verify barometric pressure signal correct Note Local barometric pressure is given in in Hg Inches of Mercury 34 millibars are...

Page 180: ...ght Circuit Open Bulb has failed or is disconnected or interconnect harness is open Correct condition C1264 Backup Reverse Light Circuit High Bulb has failed or is disconnected or interconnect harness shorted to battery power Correct condition C1265 Backup Reverse Light Circuit Low SG Bulb has failed or is disconnected or interconnect harness shorted to chassis ground Correct condition P0030 O2 He...

Page 181: ...elay removed or interconnect harness shorted to chassis ground Correct condition P0500 Vehicle Speed Sensor Sensor circuit signal intermittent or missing Correct condition start and drive the vehicle P0508 Idle Air Control System Circuit Low SG IAC interconnect harness shorted to chassis ground Correct condition P0509 Idle Air Control System Circuit High Open IAC disconnected or the interconnect h...

Page 182: ...attery defective 1 Repair tighten lead wires 2 Replace stator coils 3 Replace regulator rectifier 4 Add distilled water 5 Replace battery Problem Magneto overcharges Condition Remedy 1 Internal 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 Cond...

Page 183: ...ercharged damaged 5 Battery short circuited 6 Electrical load too high 1 Replace battery 2 Charge battery add distilled water 3 Check AC generator regulator rectifier circuit connections 4 Replace battery correct charging system 5 Replace battery 6 Reduce load Problem Battery polarity reversed Condition Remedy 1 Battery incorrectly connected 1 Reverse connections replace battery ...

Page 184: ...h time the front drive select switch is shifted If no sound is heard see the Elec trical System section If the 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 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the ac...

Page 185: ...with a nylon cable tie then install the inner fender panel Front Differential REMOVING 1 Remove the belly panel then place the vehicle on jack stands adjusted high enough to allow working from the underside of the vehicle NOTE The jack stands should be placed under the main frame to avoid contact with front suspension components 2 Remove the drain plug and drain the gear lubricant into a drain pan...

Page 186: ...screws Account for the lock nuts then move the shocks and upper A arm up and secure them with a strap PR200 13 On the XTZ scribe match marks on the front input drive flange and the front drive yoke flange then remove the cap screws securing the yoke and flange Separate the flanges but do not remove the drive shaft PR198A 14 Push the axle shaft toward the differential to release the plunge coupler ...

Page 187: ...ntial assembly from the frame mount ings then lower the differential through the frame Disassembling Input Shaft 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing GC004A 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 GC015 CD106 3 Remove the snap rings from...

Page 188: ...ing sure the sharp edge of the snap ring faces to the outside GC012 GC011 2 Install the input shaft seal making sure it is fully seated in the edge of the housing GC014 3 Lubricate the input shaft with High Performance 2 Molybdenum Disulphide Grease packing the boot ribs and splines then assemble allowing excess grease to freely escape Slight pressure on the boot will be present during assembly Se...

Page 189: ... 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 Account for and make note of the ID tag location for assembling purposes GC003 3 Using a plastic mallet tap lightly to remove the dif ferential cover Account for an O ring KX174 NOTE If...

Page 190: ...der assembly Account for shim s and mark as right side KX179 KX181 Disassembling Pinion Gear 1 Remove the internal snap ring securing the pinion bearing in the housing WC430 2 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing CC878 3 Secure the pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar and...

Page 191: ...the bearing seats Do not push the bearing too far into the pocket WC429 Shimming Procedure Shim Selection It is very important to adjust bevel gears for the proper running tolerances Gear life and gear noise are greatly affected by these tolerances therefore it is very impor tant to properly adjust any gear set prior to final assem bly The following procedure can be used on both front differ entia...

Page 192: ... install a thicker shim and recheck GC036A 3 Install the bearing flange onto the gear case cover making sure the alignment locating pin engages the locating hole in the cover then make sure the bear ing flange is completely seated in the cover GC032A GC033A 4 Install the existing shim or a 0 063 in shim on the cover side of the ring gear then place the assembled gear case cover onto the gear case ...

Page 193: ... GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008 in 3 To increase end play decrease the shim thickness To decrease end play increase the shim thickness NOTE Once proper backlash and end play are established the gear case can be assembled see Assembling Differential Assembly in this sub sec tion CC888 RING GEAR THRUST BUTT...

Page 194: ...ion 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 chamfered side toward the gear onto the cover side of the ring gear GC036B NOTE The spider and ring gear assembly must be replaced as a complete unit ...

Page 195: ...all 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 CC893 8 Place the input shaft assembly onto the gear case housing then secure with the existing cap screws Tighten to 23 ft lb NOTE If a new housing is being installed tighten the cap screws to 28 ft lb CD103 CD110 Removing Installing Axle Seal NOTE This procedure...

Page 196: ...nto the differential and install the fill plug Tighten to 16 ft lb 5 Align the scribed match marks on the front input drive flange and the front drive yoke flange then secure with the cap screws tightened to 20 ft lb PR198A 6 Push the axle shaft into the CV coupler to release the locking ring while pulling back on the CV coupler and slide the drive axle into place PR729C 7 Install the knuckle asse...

Page 197: ...d nuts Tighten to 200 ft lb then install new cotter pins PR256 12 Install the wheels and tighten in a crisscross pattern in 20 ft lb increments to 80 ft lb aluminum wheels or 45 ft lb steel wheels 13 Remove the vehicle from the support stand 14 Install the belly panel Drive Axles REMOVING REAR DRIVE AXLE 1 Secure the vehicle on a support stand to elevate the wheels 2 Set the parking brake then rem...

Page 198: ...ifferential in this section CLEANING AND INSPECTING AXLES NOTE Always clean and inspect the drive axle com ponents to determine if any service or replacement is 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 replaced with a boot kit DISASSEMBLING AXLES N...

Page 199: ... slide the drive axle into place in the gear case PR729C NOTE To ensure proper axle seating give it a light pull the axle should remain clipped in place 2 Swing the knuckle up and onto the drive axle then place the knuckle into place in the upper A arm Secure the knuckle to the A arm with a cap screw and a new lock nut Tighten to 35 ft lb 3 Place the hub into position on the axle followed by a hex...

Page 200: ...e cargo box will tilt fully rearward 1 Drain the lubricant from the rear gear case then remove both rear drive axles 2 Remove the driveline brake caliper then cut the rear most propeller shaft boot clamp and slide the boot forward 3 Remove the boot clamps on the rear driveline boot 4 Remove the two cap screws and lock nuts securing the rear gear case to the frame then remove the gear case through ...

Page 201: ... repeat steps 1 and 2 using thicker clearance too great or thinner clear ance too small until correct specification is reached REAR DRIVE INPUT SHAFT HOUSING Removing Disassembling 1 Remove the cap screws securing the rear drive input shaft housing to the rear gear case then remove the input housing assembly GZ183 2 On the XTZ model remove the clutch pack from the clutch basket then remove the sna...

Page 202: ... The clutch pack is not a serviceable compo nent If worn discolored or damaged in any way it must be replaced Assembling Installing 1 Install a new bearing into the input housing and secure with the snap ring flat side directed away from bearing GZ184 2 Using a suitable seal driver install a new oil seal into the front of the input housing until the seal is flush with the housing GZ182A 3 Apply gr...

Page 203: ...ate lubricant Hub REMOVING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel NOTE Removing or tightening of the hub nuts requires the axles be locked To lock the rear axle set the parking brake To lock the front axle turn the igni tion switch to ON select LOCK on the drive select switch then set the parking brake and turn the igni tion switch to OFF 2 Remove the co...

Page 204: ...he 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 set the parking brake PR221 4 Secure the hub assembly with the nut Tighten to 200 ft lb then secure with a new cotter pin NOTE If ...

Page 205: ...ing 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 be returned to service do not allow brake fluid to contaminate them PR237A PR238 5 Remove the caliper holder from the caliper and di...

Page 206: ...e pads for damage and excessive wear NOTE For measuring brake pads see the Periodic Maintenance section 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 discoloration or evidence of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 ...

Page 207: ...lb 7 Place a new crush washer on each side of the brake hose fitting and install it on the caliper Tighten to 20 ft lb 8 Fill the reservoir then bleed the brake system see Periodic Maintenance Hydraulic Brake System 9 Install the wheel Tighten in a crisscross pattern in 20 ft lb increments to 80 ft lb aluminum wheels or to 45 ft lb steel wheels 10 Remove the vehicle from the support stand and ver ...

Page 208: ...oir for cracks and leakage 4 Inspect the brake hose for cracks and deterioration and the condition of the banjo fittings Installing 1 Place the master cylinder into position then using three new crush washers secure the two banjo fit tings to the master cylinder Tighten to 20 ft lb 2 Secure the master cylinder assembly to the frame with two cap screws and two flange nuts Tighten to 25 ft lb 3 Inst...

Page 209: ...to push the bearing cup out of the yoke then remove the tool and the bearing cup PR359 6 Install the separator tool on the opposite side of the yoke to push the second bearing cup from the yoke then remove the tool and separate the universal joint 7 Secure the separator tool in a vise and repeat steps 4 6 to remove the bearing cups from the movable yoke PR375 INSPECTING 1 Inspect the yoke bores fo...

Page 210: ...oke from the separator tool NOTE Repeat steps 2 3 for the opposite side bear ing cup 4 Remove the separator tool from the vise and install the universal joint bearing cups and movable yoke into the fixed yoke using the same procedure as steps 2 3 except the vise cannot be used PR355 5 Check that the universal joint can be flexed freely without binding then apply multi purpose grease to the splines...

Page 211: ...Replace shaft 3 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 leak s 3 Replace seal s Problem Brake pedal travel excessive Condition Remedy 1 Brake fluid low 2 Piston seal cup wo...

Page 212: ...iner and remove the spring AF730D CLEANING AND INSPECTING 1 Clean 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 bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber spring over the shock absorber compress the spring a...

Page 213: ...e then remove the tie rod end from the knuckle 7 Remove the cap screws securing the ball joints to the knuckle PR193 8 Tap the ball joints out of the knuckle then remove the knuckle 9 Remove the lower shock absorber eyelet from the upper A arm AF626D 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remove the snap ring from the ball joint then remove the ball joint from the A ar...

Page 214: ...rm and secure with the snap ring AF616D 2 Install the A arm assemblies into the frame mounts and secure with the cap screws Only finger tighten at this time AF610D 3 Route the brake hose through the upper A arm shock absorber mount AF627D 4 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut to 35 ft lb 5 Secure the A arm assemblies to the frame mounts from step 2 Tighten ...

Page 215: ...he wheel and tighten in a crisscross pattern in 20 ft lb increments to 80 ft lb aluminum wheels or 45 ft lb steel wheels 14 Remove the vehicle from the support stand Rear A Arms REMOVING 1 Secure the vehicle on a support stand to elevate the wheels 2 Set the parking brake 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut 5 Remove the cap screws and lock nut se...

Page 216: ...axle and the slots in the nut tighten the nut until properly aligned PR196 7 Secure the shock absorber to the frame with a cap screw and new lock nut Tighten to 33 ft lb 8 Secure the shock absorber to the lower A arm with a cap screw and new lock nut Tighten to 20 ft lb 9 Secure the boot guard to the lower A arm with the two cap screws Tighten securely 10 Install the wheel and tighten in a crisscr...

Page 217: ...wheel and have it repaired professionally NOTE Be sure all tires are the specified size and have identical tread pattern Troubleshooting WARNING Make sure the vehicle is solidly supported on the sup port stand to avoid injury 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 1 Ad...

Page 218: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 857 ...

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