Arctic Cat Y-12 2008 Manual Download Page 115

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10-2

Torque Specifications

* w/Red Loctite #271

ENGINE COMPONENTS

Part

Part Bolted To

Torque

kg-m ft-lb

Oil Drain Plug

Crankcase

2.0-3.0 14.5-22.0

Spark Plug

Cylinder Head

1.2

9.0

Cylinder Head (Nut)

Cylinder

2.1

15.0

Crankcase Half*

Crankcase Half

1.0

7.0

Flywheel*

Crankshaft

3.5-4.5 25.0-32.5

Stationary Drive
Sheave*

Crankshaft

3.8

27.5

Outer Drum*

Driven Pulley/
Centrifugal Clutch

5.5

40.0

Driven Sheave

Driven Pulley/
Centrifugal Clutch

5.5

40.0

Oil Pump Gear

Oil Pump

1.0

7.0

Starter Gear Retainer

Crankcase

1.0

7.0

Starter Motor

Crankcase

1.0

7.0

Cooling Fan

Flywheel

1.0

7.0

Oil Screen/Filter Cap

Crankcase

1.0-2.0 7.0-14.5

Cam Chain Guide

Crankcase

1.0

7.0

Transmission Drain Plug Transmission

2.1-3.0 15.0-22.0

Cylinder Head
(Cap Screw)

Cylinder

1.0

7.0

Tensioner Spring Bolt

Cam Chain Ten-
sioner

0.7

5.0

Cylinder Head Cover

Cylinder Head

1.0

7.0

Drive Sprocket

Driveshaft

11.1

80.0

Engine Mount

Engine/Frame

4.5

32.5

Intake Manifold

Cylinder Head

1.0

7.0

Carburetor

Intake Manifold

0.8

6.0

DRIVE TRAIN COMPONENTS

Rear Hub

Rear Axle Shaft

6.1-8.0 44.0-58.0

Wheel

Front/Rear Hub

4.2

30.0

Centrifugal Clutch Cover Crankcase

1.0

7.0

Seal Retainer

Crankcase

1.0

7.0

Transmission Case
Cover

Transmission

2.8

20.0

Rear Sprocket

Carrier

2.7

19.5

EXHAUST COMPONENTS

Exhaust Heat Shield

Muffler

1.0

7.0

Exhaust Pipe

Cylinder Head

1.0

7.0

Muffler

Frame

3.5

25.0

BRAKE SYSTEM COMPONENTS

Brake Banjo-Fitting

Caliper

4.0

29.0

Rear Brake Caliper

Rear Axle Hub

3.0

22.0

Master Cylinder Holder

Master Cylinder

1.4

10.0

ELECTRICAL COMPONENTS

Part

Part Bolted To

Torque

kg-m ft-lb

CDI

Frame

1.0

7.0

Voltage Regulator

Frame

0.4

3.0

Stator*

Crankcase

0.8-1.2 6.0-9.0

STEERING COMPONENTS

Front Hub

Spindle Axle

6.2

45.0

Handlebar Cap

Lower Clamp

1.0

7.0

Steering Post Outer
Bearing Cap

Inner Bearing Clamp

2.8

20.0

Steering Post

Frame

3.5

25.0

CHASSIS COMPONENTS

Air Filter Housing
Assembly

Bracket

1.0

7.0

Air Intake Tube

Crankcase

1.2

9.0

Engine (10 mm)

Frame (Front)

4.5

32.5

Engine (8 mm)

Frame (Rear)

2.2

16.0

SUSPENSION COMPONENTS

Front Shock Absorber Frame/A-Arm

4.0

29.0

Rear Shock Absorber Frame/Swing Arm

4.0

29.0

Swing Arm

Frame

6.9

50.0

Swing Arm

Rear Axle Housing

4.0

29.0

A-Arm

Frame

4.0

29.0

Knuckle

A-Arm

4.0

29.0

Tie Rod End

Knuckle

2.8

20.0

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Summary of Contents for Y-12 2008

Page 1: ...int to emphasize important information The symbol WARNING identifies personal safety related informa tion Be sure to follow the directive because it deals with the possibility of severe personal injur...

Page 2: ...Periodic Maintenance Tune Up 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls 10 Aids for Maintenance 1 2 3 4 5 6 7 8 9 10 F...

Page 3: ...CONTENTS Specifications 1 2 Break In Procedure 1 2 Gasoline Oil Lubricant 1 2 Genuine Parts 1 3 Preparation For Storage 1 3 Preparation After Storage 1 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 67...

Page 4: ...are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or MTBE are acceptable gasolines RECOMMENDED ENGINE OIL The recommended oil to use is Arctic Cat 4 Cycle Oil RECOM...

Page 5: ...and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications see Section...

Page 6: ...as necessary 9 Tighten all nuts bolts cap screws and screws making sure all calibrated nuts cap screws and bolts are tightened to specifications see Section 10 10 Make sure the steering moves freely a...

Page 7: ...8 Adjusting Engine RPM Idle 2 8 Transmission Lubricant 2 8 Engine Oil 2 9 Tires 2 10 Steering Components 2 10 Drive Chain Sprockets 2 10 Suspension Shock Absorbers Bushings 2 11 Nuts Bolts Cap Screws...

Page 8: ...s Fuel Valve I C Throttle Cable I I C L A R Carburetor I C D C D Engine RPM Idle I I I A Engine Oil R I R Valve Tappet Clearance A A Transmission Lubricant Level R I Fuel Filter I I R Tires Air Pressu...

Page 9: ...follow the charger manufacturer s instructions B When using a constant current battery charger use the following Battery Charging Chart NOTE If the battery voltage is 11 5 DC Volts or less some charge...

Page 10: ...c Cat 4 Compress the element by pressing it between the palms of both hands to remove excess sol vent Do not twist or wring the element or it will develop cracks 5 Dry the element 6 Put the element in...

Page 11: ...ter on the crankcase and intake and exhaust valve adjuster screws must not have pressure on them The two punch marks on the camshaft gear are aligned with the valve cover surface and the hole in the t...

Page 12: ...charged for this test 5 While holding the throttle lever in the full open position crank the engine over with the electric starter until the gauge shows a peak reading five to 10 compression strokes N...

Page 13: ...g procedure 1 Remove the cap screw 1 securing the spark arrester assembly 2 to the rear of the muffler Account for a gasket KM139A 2 Clean the screen 3 with a brush and parts cleaning solvent Dry with...

Page 14: ...djustment then slide the rubber boot back into position Adjusting Engine RPM Idle To properly adjust the idle RPM a tachometer is necessary To adjust idle RPM use the following procedure 1 Set the bra...

Page 15: ...ne Shut the engine off then place a drain pan under the engine oil drain plug located on the left side rear of the engine under the kick starter CD634A 2 Remove the oil drain plug and drain the engine...

Page 16: ...0 21 kg cm2 3 0 psi Steering Components The following steering components should be inspected periodically to ensure safe and proper operation A Handlebar grips worn broken or loose B Handlebar bent...

Page 17: ...pection plug from the right side crankcase cover 2 Using the Arctic Cat Tachometer p n 0644 275 start the engine and run at 4000 RPM ignition timing should be 28 BTDC F mark 3 Install the timing inspe...

Page 18: ...bulb If an electrical compo nent needs to be tested for proper function see Section 5 Brake Systems Although the brake systems have been adjusted at the factory the brakes should be checked for prope...

Page 19: ...remove the brake shoes MD2042 Removing Rear Brake Pads 1 Remove the two cap screws securing the brake caliper to the axle housing then lift the caliper off the disc KM234A 2 Depress the holder pins an...

Page 20: ...the hydraulic brake lever several times to check that the brakes are firm If the brakes are not firm bleeding the system will be necessary see BLEEDING in this sub section BLEEDING To bleed the brake...

Page 21: ...securing the stationary drive sheave to the crankshaft then remove the sta tionary drive sheave Account for a washer kick starter ratchet and cooling fan CD621 5 Open the movable sheave on the driven...

Page 22: ...cap screws to specifications see Section 10 7 Install the cooling duct 8 Place the footrest cover into position and secure it to the footrest with the Phillips head cap screws Tighten to specificatio...

Page 23: ...um s worn 1 Replace brake shoe s pad s 2 Adjust free play 3 Replace brake drum s Problem Brakes drag Condition Remedy 1 Lever free play less than minimum 2 Brake shoe return spring s loose sprung 1 Ad...

Page 24: ...NGINE TRANSMISSION Table of Contents Engine Transmission 3 2 Specifications 3 2 Y 12 Table of Contents 3 3 Troubleshooting 3 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www...

Page 25: ...m 1 968 1 970 in Connecting Rod Small End Inside Diameter Max 13 06 mm 0 514 in Connecting Rod Small End Deflection Max 0 40 mm 0 0157 in Connecting Rod Big End Side to Side Max 0 05 mm 0 002 in Crank...

Page 26: ...a copper washer located at the left rear of the transmission CD632A 4 Drain the engine oil NOTE The oil drain plug is a 12 mm cap screw with a copper washer located at the lower left front of the cran...

Page 27: ...inder head DSC02099 10 Remove the intake manifold Account for the gasket DSC02043 11 Remove two 6 mm and one 8 mm cap screws securing the exhaust front pipe protective cover DSC02105 12 Remove the tai...

Page 28: ...er ator wire connectors on the left side of the frame DSC02033 15 Remove the spark plug cap then disconnect all engine related electrical connectors on the left side of the frame CD646 CD645 16 Remove...

Page 29: ...en remove the pipe DSC02039 2 Remove two cap screws and two self tapping screws securing the cooling fan cover and remove the cover DSC02046 DSC02047 3 Remove three cap screws from the cooling shroud...

Page 30: ...ling fan from the flywheel DSC02055 6 Remove the nut securing the flywheel Account for a washer DSC02057 7 Using an appropriate puller remove the fly wheel Remove the key from the crankshaft DSC02058...

Page 31: ...tator wire DSC02088 10 Remove four cap screws securing the stator and source coil then remove the stator DSC02089 DSC02090 DSC02091 11 Remove the two cap screws securing the starter motor then remove...

Page 32: ...en remove the spark plug DSC02064 14 Remove four nuts securing the cylinder head to the cylinder DSC02066 15 Remove the two cap screws securing the cam chain tensioner to the cylinder then remove the...

Page 33: ...4 DSC02077 18 Remove the bottom chain guide then remove the cylinder Account for two dowel pins located between the crankcase and the cylinder DSC02078 DSC02084 19 Using a needle nose pliers remove th...

Page 34: ...the rear brake cable clip DSC02118 DSC02120 DSC02122 22 Remove the fixed drive face from the crankshaft Account for the washer ratchet and cooling fan CD621 23 Remove the movable drive face Account f...

Page 35: ...35 28 Remove the 14 mm nut securing the counter shaft sprocket to the countershaft NOTE When removing the countershaft sprocket with the engine out of the frame it will be necessary to hold the sprock...

Page 36: ...t Note the location of two longer cap screws and two alignment pins for assembling purposes DSC02142 DSC02144 31 Remove the bearing and inner seal from the out put side of the transmission case AT THI...

Page 37: ...ews for assembling purposes DSC02149 34 Remove the 6 mm nut and oil pump sprocket DSC02151 35 Remove the three cap screws securing the oil pump assembly then remove the oil pump assembly Account for t...

Page 38: ...crew securing the cam chain tensioner then remove the cam chain tensioner Inspect the O ring on the cap screw for damage DSC02163 DSC02166 40 Using a seal driver or socket from the inside remove the l...

Page 39: ...nes note the location of each ring for proper installation When installing new rings install as a complete set only CLEANING INSPECTING PISTON RINGS 1 Take an old piston ring and snap it into two piec...

Page 40: ...ected toward the piston dome Stagger the ring end gaps according to the illus tration Cylinder Cylinder Head CLEANING INSPECTING CYLINDER HEAD 1 Using a non metallic carbon removal tool remove any car...

Page 41: ...ust not exceed specifications MEASURING CYLINDER HEAD DISTORTION 1 Lay a straightedge across the cylinder head then using a thickness gauge check the distortion between the head and the straightedge C...

Page 42: ...TE To produce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly clean...

Page 43: ...fications DSC02209 2 Using a calipers measure the outside diameter of the collar in the movable drive face Measure ment must be equal to or greater than minimum specifications DSC02211 3 Using a calip...

Page 44: ...housing 2 Using a thickness gauge measure the clearance between the outer rotor and housing Measure ment must be equal to or less than maximum specifications DSC02220 3 Using a thickness gauge measur...

Page 45: ...lf DSC02212 DSC02213 3 Rotate the crankshaft and the connecting rod assembly to locate the connecting rod in the cen ter of the cylinder opening DSC02214 4 Install a new gasket and two dowel pins on t...

Page 46: ...surfaces must be clean before installing the gasket 10 Install the eight cap screws to the right side crankcase cover Apply red Loctite 271 on the cap screws and tighten to specifications NOTE Note t...

Page 47: ...n on the mounting towers Secure with two cap screws tightened to specifications DSC02237 DSC02240B 13 Press the flywheel key into the crankshaft key way and install the flywheel on the crankshaft Inst...

Page 48: ...l expander ring in the bottom ring groove of the piston then install the lower and upper scraper rings over the expander making sure the ends of the expander do not overlap Stagger the scraper end gap...

Page 49: ...n dome directed toward the intake port then seat the piston pin against the installed circlip and install the second circlip with the opening directed toward the skirt or pis ton dome DSC02259 NOTE Ma...

Page 50: ...ring DSC02280 DSC02250 25 Install the two alignment pins and the cylinder head gasket onto cylinder Pull the chain out through the gasket and cylinder head making sure the alignment pins seat properly...

Page 51: ...the rocker arm shafts must be aligned with the holes in the shaft supports DSC02266 DSC02267 DSC02268 29 Install the two alignment pins and the camshaft holder onto the cylinder head Using a screw dri...

Page 52: ...tions DSC02066 31 Remove the cap screw from the chain tensioner body Account for the spring and the washer DSC02291 32 Depress the ratchet and retract the rod then install the chain tensioner body to...

Page 53: ...he cylinder head cover and secure with four cap screws Tighten to specifications DSC02289 38 Inspect the transmission bearings and oil seals Replace any worn or broken seals with new ones Replace any...

Page 54: ...stall the countershaft sprocket with the spacer to the inside and tighten the lock nut to specifi cations DSC02320 DSC0232 43 Install the centrifugal clutch assembly to the driven pulley by compressin...

Page 55: ...cap screws to specifica tions DSC02306 47 Install the starter one way gear DSC02305 48 Install the drive face collar into movable drive face and the ramp plate taking care that the six roller guides...

Page 56: ...r with a hose bracket Tighten to specifications DSC02325 54 Install the top cylinder shroud clamp and the bottom shroud Tighten two cap screws on each side Install the cooling fan cover and secure wit...

Page 57: ...ft side of the frame DSC02033 3 Install the drive chain then connect with the master link and plate Install the clip with the open end directed opposite of chain rotation 4 Install the tailpipe at the...

Page 58: ...with appropriate grade gaso line 9 Connect the ground wire to the drive belt cover 10 Connect the battery positive cable first then the negative cable 11 Start the engine and allow to warm up then ch...

Page 59: ...Clean vent hose 2 Replace needle 3 Clean replace hose 4 Clean replace inlet screen valve screen Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defect...

Page 60: ...ston rings cylinder worn 2 Cylinder wall scored scuffed 3 Crankcase over full of oil 4 Air filter too much air filter element oil 5 Carburetor jets incorrect size too big 1 Replace service rings cylin...

Page 61: ...filter screen obstructed 6 Float level low 7 Intake manifold leaking air 8 Air filter element obstructed 1 Clean piston 2 Add engine oil 3 Drain replace gasoline 4 Replace pump 5 Clean filter screen...

Page 62: ...uretor Schematic 4 2 Carburetor 4 2 Throttle Cable Free Play 4 7 Engine RPM Idle 4 7 Gas Tank 4 7 Fuel Valve 4 9 Gas Vent Hoses 4 9 Oil Pump Assembly 4 9 Oil Screen Filter 4 9 Troubleshooting 4 10 FOR...

Page 63: ...Cable Free Play at lever 6 0 mm 0 25 in KEY 1 Carburetor Body 2 O Ring 3 Set Plate 4 Screw w Washer 5 Choke Assembly 6 Jet Needle 7 Carburetor Cap 8 Gasket 9 Throttle Valve Spring 10 Throttle Valve 11...

Page 64: ...assembly then remove the assembly Account for the washers and the O ring 2 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the seal and the washers CD60...

Page 65: ...ks nicks stripped threads and any other imperfections in the casting 6 Inspect float for damage 7 Inspect gasket seal and O rings for distortion tears or noticeable damage 8 Inspect tips of the jet ne...

Page 66: ...idle adjustment screw with the spring 5 Install the float and needle valve assembly into the carburetor then install the float pin CD763 NOTE Check float arm height by inverting the carburetor freein...

Page 67: ...NG 1 Install the throttle valve into the carburetor with the machined groove engaging the guide pin then install the jet needle needle clip needle clip plate and gasket 2 Thread the carburetor cap ont...

Page 68: ...2139 6 Carefully lay the handlebar assembly forward on the front fender panel NOTE To access the gas tank it is necessary to move the front fender panel which requires removing the handlebar from its...

Page 69: ...nstall the gas hoses to the fuel valve on the frame according to the tags made during remov ing MD2394 2 Install and tighten the gas tank cap screws to specifications see Section 10 NOTE Do not over t...

Page 70: ...ank one to the carburetor 2 Remove the gas hoses from the valve by releas ing the spring clamps 3 Inspect for and remove any obstructions in the valve INSTALLING 1 Install the gas hoses onto the valve...

Page 71: ...lem Medium or high speed impaired Condition Remedy 1 Main jet obstructed 2 Needle jet obstructed 3 Throttle valve not operating properly 4 Filter obstructed 5 Float level incorrect 1 Clean main jet 2...

Page 72: ...Stator Magneto Coil 5 3 Choke Circuit 5 3 Battery 5 3 Brakelight Switch 5 3 Fuse 5 4 Ignition Coil 5 4 Ignition Switch 5 4 Handlebar Control Switches 5 5 Magneto Assembly 5 5 Starter Motor 5 6 Regulat...

Page 73: ...e wire then connect the black tester lead to a suitable ground 3 The meter must read 80 160 ohms CDI Ignition Coil Disconnect the wires at the coil PEAK VOLTAGE NOTE All of the peak voltage tests shou...

Page 74: ...idual single con nectors located beneath the left front fender NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Connector 1 Set the meter selector to the DC Voltage position...

Page 75: ...does not read as specified replace the spark plug cap Ignition Switch The connector is accessible below the front fender panel in front of the steering post VOLTAGE NOTE Perform this test on the harne...

Page 76: ...ot or replace the switch component the connector or the switch wiring harness Magneto Assembly REMOVING 1 Disconnect the battery 2 Remove the flywheel from the engine see Section 3 3 Remove the stator...

Page 77: ...the regulator rectifier plugged in 3 With the engine running at a constant 3000 RPM the meter must read 12 1 15 2 volts Ignition Timing The ignition timing cannot be adjusted however veri fying igniti...

Page 78: ...o coils shorted grounded open 3 Regulator rectifier shorted punctured 1 Repair replace tighten lead wires 2 Replace magneto coils 3 Replace regulator rectifier Problem Magneto charges but charging rat...

Page 79: ...te contaminated 1 Replace battery 2 Charge battery 3 Replace battery 4 Replace battery Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Specific gravity too high 3...

Page 80: ...ONTENTS Drive System 6 2 Reduction Gears 6 2 Drive Chain Sprockets 6 4 Rear Hub Drive Axle 6 7 Front Hub 6 10 Brake Systems 6 12 Troubleshooting 6 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 962...

Page 81: ...en head cap screws secur ing the cover to the gear reduction case Discard the gasket MD1890 NOTE There will be residual lubricant inside the gear reduction case when the cover is removed MD1892 MD1891...

Page 82: ...aring MD1927 3 Install the bearing retaining washer and the 6 mm cap screw Tighten to specifications MD1926 4 Install the intermediate gear and the gear reduc tion case cover gasket Account for the tw...

Page 83: ...ockets excessive wear hooking missing or broken teeth ADJUSTING DRIVE CHAIN 1 Loosen the four cap screws A securing the rear axle housing to the rear swing arm KM217A KM212A 2 Tighten the adjuster nut...

Page 84: ...oving Drive Chain in this sub section 3 Remove the countershaft sprocket Account for a washer INSTALLING FRONT COUNTERSHAFT SPROCKET 1 Place the countershaft sprocket over the coun tershaft 2 Install...

Page 85: ...rrier then remove the sprocket INSTALLING REAR SPROCKET 1 Position the sprocket onto the sprocket carrier then install the three cap screws securing the sprocket to the sprocket carrier Tighten the ca...

Page 86: ...the wheels and hubs see Removing Rear Hub Drive Axle in this sub section 3 Using an appropriate prying tool carefully pry out the seals from each side of the axle housing KM232 4 Drive out the bearing...

Page 87: ...s to determine if any service or replace ment is necessary Replace all components that show signs of wear or damage 1 Using a clean towel wipe away any oil or grease 2 Inspect bearings for smooth oper...

Page 88: ...g to the swing arm 2 Install the brake caliper to the axle housing KM207 3 Install the drive chain see Installing Drive Chain sub section 4 Adjust the drive chain slack see Adjusting Drive Chain sub s...

Page 89: ...1 Secure the ATV on a support stand to elevate the front wheels then remove the wheels MD2421 2 Remove the cotter pin from the castle nut NOTE During installing a new cotter pin should be installed 3...

Page 90: ...r a spacer MD2384A 3 Repeat procedure for the other hub INSTALLING HUB BEARINGS AND SEALS 1 Lightly lubricate the bearings with bearing grease then using a plastic mallet and a bearing driver or appro...

Page 91: ...roken 3 Rear sprocket worn broken 4 Chain slipped off sprockets 5 Master link worn broken missing 1 Replace chain 2 Replace countershaft sprocket 3 Replace rear sprocket 4 Replace adjust drive chain 5...

Page 92: ...USPENSION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 A Arm 7 3 Swing Arm 7 6 Wheels and Tires 7 8 Troubleshooting 7 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www...

Page 93: ...and to release the load on the suspen sion 2 Remove the cap screw securing the rear shock absorber to the frame MD2314 3 Remove the cap screw securing the rear shock absorber to the swing arm then rem...

Page 94: ...d INSTALLING REAR SHOCK ABSORBER 1 Place the spring preload adjuster and spring over the shock absorber Compress the spring and install the retainer 2 Place the shock absorber into position on the fra...

Page 95: ...steering knuckle assembly from the A arm MD2113 7 Remove the cap screw and self locking nut securing the shock absorber to the A arm MD2132 8 Remove the cap screws and self locking nuts securing the A...

Page 96: ...the rubber spindle pin boot MD2427 4 Install the tie rod end into the steering knuckle and secure it with the self locking nut Tighten the nut to specifications then install a new cot ter pin MD2426...

Page 97: ...omponents attached if necessary 4 Remove the four cap screws A securing the axle housing to the swing arm then remove the axle housing KM217B KM212A 5 Remove the cap screws securing the skid plate and...

Page 98: ...coat of grease then install the spacer into the swing arm 2 If removed install the rubber swing arm guard 3 Lubricate the two seals with a light coat of grease then install them on the ends of the sw...

Page 99: ...els 2 Remove the four cap screws securing each wheel then remove the wheels NOTE Keep left side and right side wheels sepa rated for installing them on their proper sides WARNING After removing and in...

Page 100: ...or punctures NOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Be sure all tires are the specified size and hav...

Page 101: ...Tighten cap screws 2 Replace bushings Problem Rear wheel oscillation Condition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loo...

Page 102: ...STEERING FRAME TABLE OF CONTENTS Steering Frame 8 2 Steering Post Handlebar Tie Rods 8 2 Handlebar Grip 8 6 Troubleshooting 8 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www...

Page 103: ...through the metal loop on the steering post and out of the way MD2430 MD2431 3 Remove the handlebar MD2139 4 Disconnect the handlebar switch assembly and brake switch connectors then route them throu...

Page 104: ...removed MD2142 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Wash the tie rod ends in parts cleaning solvent Dry with compre...

Page 105: ...fications Install a new cotter pin MD2418 3 Install the inner tie rod ends Tighten the nuts to specifications and install new cotter pins MD2419 4 Route the control cables and wiring through the meta...

Page 106: ...king or binding MD2105 MD2441 MD2106 9 Connect the handlebar switch assembly and brake switch connectors MD2434 MD2445 10 Install the seat WARNING Make sure that there is maximum right left steering c...

Page 107: ...cessary 1 Inspect the grip for wear cuts or cracks 2 Inspect the grip for deterioration INSTALLING NOTE Before installing a handlebar grip use contact spray or alcohol to clean the inside of the grip...

Page 108: ...ghten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber...

Page 109: ...9 1 9 SECTION 9 CONTROLS TABLE OF CONTENTS Handlebar Switch 9 2 Hand Brake Lever Assemblies 9 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com...

Page 110: ...g connectors MD2438 3 Remove the handlebar switch assembly from the handlebar KM544 MD2436 INSTALLING 1 Place the handlebar switch assembly onto the handlebar Tighten the screw securely MD2436 KM544 2...

Page 111: ...move the front brake cables from their adjust ers by screwing the adjusters inward to loosen the cables then pulling them free MD2449 4 Loosen the 6 mm Allen head screw securing the front brake lever...

Page 112: ...e lever assembly to the handlebar and remove the hand brake master cylinder assembly KM208A MD2442 INSTALLING 1 Slide the right brake lever assembly onto the handlebar do not tighten the Allen head sc...

Page 113: ...on 8 Tighten the brakeline hose bolt to specifications see Section 10 then check the rear brake oper ation The brake lever should be firm and the rear brake should stop the wheels NOTE If the brake is...

Page 114: ...10 1 10 SECTION 10 AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications 10 2 Torque Conversions 10 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com...

Page 115: ...eel Front Rear Hub 4 2 30 0 Centrifugal Clutch Cover Crankcase 1 0 7 0 Seal Retainer Crankcase 1 0 7 0 Transmission Case Cover Transmission 2 8 20 0 Rear Sprocket Carrier 2 7 19 5 EXHAUST COMPONENTS E...

Page 116: ...68 9 4 88 12 2 9 1 2 29 4 0 49 6 8 69 9 5 89 12 3 10 1 4 30 4 2 50 6 9 70 9 7 90 12 5 11 1 5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14...

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