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6-15

CC901

NOTE: Prior to installing the seal, apply High Per-

formance #2 Molybdenum Disulphide Grease to
the seal outside diameter.

4. Using an appropriate seal installation tool, evenly

press the seal into the cover bore until seated.

CF278

5. Repeat steps 1-4 for the opposite side.

INSTALLING DIFFERENTIAL

1. Align the splined input yoke with the front output

splines; then place the differential into position on

the frame and install the cap screws, washers, and

flex-lock nuts. Tighten to 38 ft-lb. Make sure the

rubber boot is properly seated on the input yoke.

CD857

CD859

2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid

lubricant into the differential and install the filler

plug. Tighten to 16 ft-lb.

3. Install the front drive actuator with the three

torx-head cap screws; then connect the wire con-

nector to the main wiring harness.

AG925

4. Install the inner fender panels.

5. Install the front axles (see Drive Axles in this sec-

tion).

6. Secure the upper A-arms with cap screws and lock

nuts. Tighten to 35 ft-lb.

AF610D

7. Secure the lower shock eyelets with cap screws

and lock nuts. Tighten to 35 ft-lb.

! CAUTION

Make sure the tool is free of nicks or sharp edges or
the seal will be damaged.

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

www.mymowerparts.com

Содержание 08 ATV

Страница 1: ...bol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death The symbol CAUTION identifies u...

Страница 2: ...to go Section 1 General Information Specifications 2 Periodic Maintenance 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls I...

Страница 3: ...ications 1 2 Torque Conversions ft lb N m 1 3 Tightening Torque General Bolts 1 3 Break In Procedure 1 3 Gasoline Oil Lubricant 1 3 Genuine Parts 1 4 Preparation For Storage 1 4 Preparation After Stor...

Страница 4: ...USPENSION COMPONENTS Front Part Part Bolted To Torque ft lb N m A Arm Frame 50 68 Knuckle Ball Joint 35 47 Shock Absorber Frame 50 68 Shock Absorber Upper A Arm 50 68 SUSPENSION COMPONENTS Rear Shock...

Страница 5: ...ed gasoline to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE...

Страница 6: ...cision made to ensure high quality and correct fit Refer to the appro priate Illustrated Parts Manual for the correct part number quantity and description Preparation For Storage Arctic Cat recommends...

Страница 7: ...ut of storage and correctly preparing it will assure many miles and hours of trouble free riding Arctic Cat recommends the following proce dure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean th...

Страница 8: ...M Idle 2 9 Engine Transmission Oil Filter Strainer 2 9 Front Differential Rear Drive Lubricant 2 11 Tires 2 11 Steering Components 2 11 Driveshaft Coupling 2 12 Suspension Shock Absorbers Bushings 2 1...

Страница 9: ...on Oil Level I A Engine Transmission Oil Filter R R R Oil Strainer I I C Front Differential Rear Drive Lubricant I I R 4 Yrs Tires Air Pressure I I R Steering Components I I I R V Belt I l R Suspensio...

Страница 10: ...oroughly wash the battery and battery com partment with soap and water NOTE If battery posts cable ends or the battery case has a build up of white green powder residue apply water and baking soda to...

Страница 11: ...trical system failure always check the fuses first NOTE To remove a fuse compress the locking tabs on either side of the fuse case and lift out 1411 526 Air Filter Use the following procedure to remov...

Страница 12: ...sure it is properly positioned and properly seated with the filter frame down GZ019 10 Install the air filter housing cover and secure with the wing nuts 11 Install the storage compartment then secur...

Страница 13: ...the cap screw and install the crankcase and cap 6 Place the two tappet covers into position making sure the proper cap screws are with the proper cover Tighten the cap screws securely Valve Tappet Cle...

Страница 14: ...all the spark plugs then install the timing inspection plug and crankshaft end cap Testing Engine Compression To test engine compression use the following proce dure 1 Remove the high tension leads fr...

Страница 15: ...intervals shown in the Periodic Maintenance Chart clean the spark arrester using the following pro cedure 1 Remove the three cap screws securing the spark arrester assembly to the muffler then loosen...

Страница 16: ...sion Oil Filter Strainer OIL FILTER The engine should always be warm when the oil is changed so the oil will drain easily and completely 1 Park the ATV on level ground 2 Remove the oil level stick fil...

Страница 17: ...ws securing the strainer then remove the strainer NOTE Thoroughly clean any sealant from the oil strainer cap CC163D 4 Place the oil strainer into position beneath the crankcase and secure with the ca...

Страница 18: ...s NOTE If the differential rear drive oil is contami nated with water inspect the drain plug filler plug and or bladder Tires TIRE SIZES The ATV is equipped with low pressure tubeless tires of the siz...

Страница 19: ...ooting other components To verify ignition timing use the follow ing procedure 1 Attach the Timing Light to either spark plug high tension lead then remove the timing inspection plug from the left sid...

Страница 20: ...0070C NOTE There should be an average operating load on the ATV when adjusting the headlight aim 2 Measure the distance from the floor to the mid point of each headlight 3 Using the measurements obtai...

Страница 21: ...the circuit Troubleshoot the harness connec tors gear shift position connector gear shift posi tion switch and LCD connector Frame Welds Racks The frame welds and racks should be checked period icall...

Страница 22: ...e sys tem D Repeat step C until the brake lever is firm E At this point perform step B C and D on the other FRONT bleeder screw then move to the REAR bleeder screw and follow the same pro cedure 4 Car...

Страница 23: ...h brake system five times 4 Adjust the auxiliary brake if necessary 5 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed Coolant When filling the...

Страница 24: ...ove the face Account for the spacer GZ074 5 Remove the V belt GZ085 INSTALLING 1 Spread the faces of the driven clutch by threading in a push bolt then when the faces are separated insert the belt and...

Страница 25: ...rubber boot A off the adjuster then loosen the jam nut B Turn the adjuster C to achieve 1 4 in of free play measured at the end of the differential lock lever CD560A 2 Select the 2WD position on the...

Страница 26: ...ANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 Thundercat Table of Contents 3 6 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561...

Страница 27: ...ength min 3 97 mm 0 156 in Valve Face Seat Width intake exhaust 2 25 mm 0 0886 in 2 60 mm 0 1024 in Valve Seat Angle intake exhaust 45 15 45 30 Valve Face Radial Runout max 0 2 mm 0 0079 in Valve Spri...

Страница 28: ...Clean replace hose 3 Clean replace inlet screen valve screen 4 Replace fuel pump Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 ECU defective 4 Fuel injector...

Страница 29: ...ECU defective 6 Spark plug fouled gap too wide 7 Ignition coil defective 8 Fuel injector obstructed 1 Adjust clearance 2 Replace service seats valves 3 Replace guides 4 Replace arms shafts 5 Replace E...

Страница 30: ...ean element 11 Drain excess oil change oil 12 Tighten replace manifold 13 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 2 Oil low 3 Octane low gas...

Страница 31: ...negative battery cable 2 Remove the front rack gauge pod footwells and footrests then remove the front body panel see Section 8 3 Disconnect the IAT sensor connector then loosen the clamp securing the...

Страница 32: ...onnect the fuel injector wiring connectors then remove the intake manifolds leaving the injectors installed GZ106 GZ107 8 Disconnect the stator coil connector and the crank shaft position sensor conne...

Страница 33: ...exhaust pipe to the cylinder then remove the springs securing the rear exhaust pipe to the front exhaust pipe and remove the rear exhaust pipe Account for a grafoil seal on the pipe juncture and a se...

Страница 34: ...ter pump then after coolant has drained apply compressed air to the bleed opening to purge the remaining coolant from the system Install the bleed screw and radiator drain plug and tighten securely GZ...

Страница 35: ...t is in the vertical plane then raise the front of the engine transmission until the front drive splines disengage from the differential GZ 110A GZ117A 22 Fold the front drive line up and secure again...

Страница 36: ...the compression stroke GZ027 GZ026 NOTE Timing marks on the rotor flywheel are stamped with an F front cylinder and R rear cylinder adjacent to the mark GZ063 GZ059 2 Remove the tappet covers on the...

Страница 37: ...C ring into the crankcase GZ155 6 Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft then drop the sprocket off the camshaft GZ154A 7 While holding the chain...

Страница 38: ...e other cylinder head C Cylinders D Pistons NOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the cap screws securing the water hose union to the cylinder then remove...

Страница 39: ...set only If the piston rings must be removed remove them in this sequence A Starting with the top ring slide one end of the ring out of the ring groove B Remove each ring by working it toward the dome...

Страница 40: ...ttained CC130D Removing Valves NOTE Keep all valves and valve components as a set Note the original location of each valve set for use during installation Return each valve set to its original locatio...

Страница 41: ...ve 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 place the cylin...

Страница 42: ...sing the valve spring compressor compress the valve springs and install the valve cotters PISTON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspec...

Страница 43: ...n 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 specifications the piston pin must be replaced ATV 1070 2 In...

Страница 44: ...combustion chamber or the sealing 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 cov ered...

Страница 45: ...de is damaged it must be replaced Inspecting Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locations from top to bottom and again from...

Страница 46: ...marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Remove the adjuster screws and jam nuts CC005D 2 Place a strip of plasti gauge in...

Страница 47: ...espective cylinder GZ166 2 Place the two alignment pins into position Place the cylinder gasket into position then place a pis ton holder or suitable substitute beneath the pis ton skirt and square th...

Страница 48: ...chain through the cylinder head GZ151 8 Install the four cylinder head cap screws with washers Tighten only until snug GZ132B 9 Loosely install the five cylinder head nuts 10 In a crisscross pattern t...

Страница 49: ...ing the camshaft is necessary for alignment do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position GZ190A 14 Seat the cam sprocket onto the camshaft making...

Страница 50: ...mshaft sprocket assembly through the chain and towards its seating position then loop the chain over the sprocket NOTE Note the position of the alignment marks on the end of the camshaft They must NOT...

Страница 51: ...nment hole ATV 1027 23 Install the first cap screw threads coated with red Loctite 271 securing the sprocket and tab washer to the camshaft Tighten only until snug GZ195 24 Rotate the crankshaft until...

Страница 52: ...ockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clock wise The adjuster shaft tension will be released in step 30 29 Pla...

Страница 53: ...screws must not have pressure on them 34 Install the top side cap screws with rubber wash ers then install the remaining cap screws Tighten only until snug CC003D 35 In a crisscross pattern starting f...

Страница 54: ...ntershaft bushing B and starter coun tershaft gear C then remove the starter gear shafts D noting that the longer shaft is nearest the starter GZ224A NOTE The starter is not serviceable and must be re...

Страница 55: ...and must be replaced as a complete assembly 8 Remove the cap screws securing the gear shift cover to the crankcase then remove the gear shift cover Account for a gasket and washer NOTE Inspect the ins...

Страница 56: ...ing the oil filler cover to the crankcase then remove the cover Account for an O ring GZ250 Installing Left Side Components 1 Thoroughly clean all gasket material and sealant from mating surfaces 2 In...

Страница 57: ...hift cam stopper assembly into the crankcase and tighten to 8 ft lb GZ255 GZ256 6 Install the shift cam stopper spring onto the shift stopper and secure with a flat washer and flange nut Tighten to 8...

Страница 58: ...nkshaft surface and rotor flywheel bore and install the rotor flywheel onto the crankshaft aligning the keyway with the key Secure with the nut and tighten to 107 ft lb GZ225 12 Install the starter dr...

Страница 59: ...not have to be removed from the frame for this procedure Removing Right Side Components A V Belt Cover B Driven Pulley C Clutch Cover D Centrifugal Clutch 1 Remove the cap screws securing the V belt c...

Страница 60: ...the cap screws securing the clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pins GZ246B GZ247A NOTE To aid in installing it is recommended that the assemb...

Страница 61: ...embly GZ248A Servicing Right Side Components NOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary INSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspe...

Страница 62: ...able component If the pulley faces cam ramps or sheeve bushing are worn or loose the pulley must be replaced as an assembly Do not disassemble the driven pulley Installing Right Side Components 1 Inst...

Страница 63: ...rrectly installed place a bead of silicone sealant on the mating surfaces and install the V belt housing Secure with the cap screws tightened to 8 ft lb GZ263 GZ244A 9 Place the driven pulley assembly...

Страница 64: ...then install the cover and secure with the cap screws Tighten the cap screws to 8 ft lb Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Comple...

Страница 65: ...mbled sec ondary gear sets will have to be reset for backlash and gear contact see Servicing Crankcase Com ponents in this section 4 Remove one cap screw from the right side crank case and eight cap s...

Страница 66: ...uring the water pump drive idler B to the idler shaft then remove the drive idler GZ299A 3 Remove the water pump driven shaft C Account for the driven gear and drive pin GZ304A 4 Remove the snap ring...

Страница 67: ...must be secured to the front shaft or false measurements will occur Checking Backlash NOTE The rear shaft and bevel gear must be removed for this procedure Also always start with the original shims o...

Страница 68: ...t NOTE If tooth contact pattern is comparable to the correct pattern illustration no correction is necessary If tooth contact pattern is comparable to an incorrect pattern correct tooth contact accord...

Страница 69: ...aft and drive pin for excessive 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 th...

Страница 70: ...indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the small end of the connecting rod away from the dial indicator 3 Maximum deflection m...

Страница 71: ...the positions for 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 driv...

Страница 72: ...her then remove the low driven gear locking washer GZ320 GZ319 GZ318A 6 Remove the low driven gear Account for a bear ing bushing and thrust washer GZ316 Assembling 1 From the drive gear end install a...

Страница 73: ...l the reverse driven gear 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 bushing an...

Страница 74: ...in the crankcase and secure with two cap screws Coat the threads with blue Loctite 243 and tighten securely to 8 ft lb GZ305 2 Install a flat washer drive pin and drive gear onto the oil pump shaft th...

Страница 75: ...rankcase GZ332 GZ333 7 Install the gear shift shaft into the crankcase mak ing sure the flat washer is in place on the gear shift position switch end and the bearing assembly on the gear shift stop en...

Страница 76: ...y placing the left side crankcase onto the assembled right side Secure with the cap screws eight left side and one right side GZ342 5 Tighten the cap screws to 8 ft lb using the pattern shown and turn...

Страница 77: ...cap screws Tighten to 20 ft lb 5 Align the engine with the mounting brackets and install the through bolts with flat washers then install the flange nuts and tighten to 45 ft lb 6 Connect the coolant...

Страница 78: ...take manifolds and tighten to 8 ft lb then install the throttle body and secure with the hose clamps GZ106 GZ107 GZ090B 12 Connect the fuel injector TPS connector A MAP sensor connector C and ISC valv...

Страница 79: ...trests foot wells and front rack then install the upper bumper sup port to frame cap screws and tighten to 35 ft lb 18 Connect the negative battery cable then secure the battery with the tool tray and...

Страница 80: ...Play 4 3 Gas Tank 4 4 Oil Filter Oil Pump 4 4 Testing Oil Pump Pressure 4 4 Oil Cooler 4 5 Liquid Cooling System 4 5 Radiator 4 5 Hoses Thermostat 4 6 Fan 4 6 Water Pump 4 6 Electric Fuel Pump Fuel L...

Страница 81: ...rmal speed NOTE A fully charged battery must read at least 12 5 DC volts no load A minimum of 8 5 DC volts under load is necessary for the EFI system to operate 5 Check the air filter housing and air...

Страница 82: ...e sen sors then install the air filter housing and connect all hoses Tighten all clamps securely GZ094B GZ091A 3 Connect the wiring connector to the IAT sensor 4 Install the front rack and body panel...

Страница 83: ...rt the engine and inspect for leakage 6 Install the rear fenders right rear tire and rack then install the seat making sure it latches securely Oil Filter Oil Pump NOTE Whenever internal engine compon...

Страница 84: ...he radi ator to the frame 6 Disconnect the fan wiring from the main wiring harness then remove the radiator fan assembly and account for the grommets and collars 7 Remove the fan fan shroud assembly f...

Страница 85: ...ostat should start to open at 73 5 76 5 C 164 170 F D If the thermostat does not open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear NOTE All...

Страница 86: ...ant leaks then add coolant if necessary to proper level Electric Fuel Pump Fuel Level Sensor The electric fuel pump and fuel level sensor are not serviceable components If either component fails it mu...

Страница 87: ...oat lever through the opening in the gas tank 5 Using duct tape or other suitable means cover the fuel pump opening INSPECTING 1 Inspect the fuel screen and blow clean with low pressure compressed air...

Страница 88: ...lever clearance 4 Connect the wires fuel hose and spring clamp then turn the ignition switch to the ON position Note that the fuel pump runs momentarily and the fuel gauge indicates the proper fuel l...

Страница 89: ...Ignition Switch 5 7 Handlebar Control Switches 5 8 Front Drive Selector Switch 5 9 Front Drive Selector Actuator 5 9 Differential Lock Switch 5 10 Stator Coil Crankshaft Position CKP Sensor 5 10 Star...

Страница 90: ...ed NOTE For absolute accuracy all tests should be made at room temperature of 68 F Accessory Receptacle Connector NOTE This test procedure is for either the recep tacle or the connector VOLTAGE 1 Turn...

Страница 91: ...ed tester lead to one black wire then connect the black tester lead to the other black wire AR626D 3 When the brake pedal is depressed the meter must show less than 1 ohm NOTE If the meter shows more...

Страница 92: ...en the temperature reaches 100 C 212 F the meter should read approxi mately 155 ohms 5 If the readings are not as indicated the sensor must be replaced 6 Install the sensor and tighten securely 7 Conn...

Страница 93: ...fuse holder connector terminal the other side will show no voltage NOTE When testing the HI fuse holder the head light dimmer switch must be in the HI position when testing the LIGHTS fuse holder the...

Страница 94: ...r Coil Crankshaft Position CKP Sensor in this section MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 1 Disconnect the MAP connector from the pressure sensor located on top of the throttle body 2 Select DC Volt...

Страница 95: ...housing with new O ring lightly coated with multi purpose grease then secure the sensor with the Allen head cap screw threads coated with blue Loctite 242 Tighten securely CD071 Ignition Switch The ig...

Страница 96: ...TE If the meter shows more than 1 ohm of resistance troubleshoot or replace the switch component the connector or the switch wiring harness RESISTANCE LO Beam 1 Connect the red tester lead to the whit...

Страница 97: ...e connector disconnected and on the selector side of the connector RESISTANCE 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the red wire then connect the black tester...

Страница 98: ...cted and the black tester lead to ground CD575 2 Turn the ignition switch to the ON position The meter must show 12 DC volts NOTE If no voltage is indicated check the wiring harness fuse or battery co...

Страница 99: ...charge for this test Crankshaft Position Sensor 1 Set the meter selector to the AC Voltage position 2 Connect the red tester lead to the blue wire then connect the black tester lead to the green wire...

Страница 100: ...ct the black tester lead to ground 3 With the starter button depressed the meter must show approximately 10 0 DC volts and the starter motor should operate AR607D NOTE If the meter showed correct volt...

Страница 101: ...re not a serviceable component and must be replaced as an assembly Headlights The connectors are the four 2 prong ones secured to the front bumper supports two on each side with cable ties BULB VERIFI...

Страница 102: ...adjusted for this procedure 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the red blue wire then connect the black tester lead to the black wire 3 With either b...

Страница 103: ...iagnostic harness then install the black rubber cap 4 Install the seat making sure it locks securely in place Tilt Sensor SUPPLY VOLTAGE 1 Disconnect the three wire connector from the sen sor then sel...

Страница 104: ...after testing make sure the arrow marking is directed up CD705A Throttle Position Sensor TPS INSPECTING 1 Remove the right side engine cover then discon nect the three wire TPS connector plug GZ095A N...

Страница 105: ...on the meter and turn the ignition switch to the ON position The meter should read approximately 1 12 DC volts with the throttle full open and approximately 4 32 DC volts with the throttle in the clos...

Страница 106: ...f the TPS indicator icon A B or C then adjust the TPS until the TPS icon appears in the center position B FI459A FI454A FI459B 5 Tighten the mounting screws securely then verify the TPS icon appears i...

Страница 107: ...1 Change to correct gasoline 2 Clean element 3 Replace plug 4 Replace seals 5 Replace rings Problem Spark plug electrodes overheat or burn Condition Remedy 1 Spark plug incorrect too hot 2 Engine over...

Страница 108: ...onnections loose disconnected 1 Charge replace battery 2 Replace switch 3 Repair replace brushes 4 Replace relay 5 Turn on switches 6 Connect tighten repair connections Problem Battery sulfation Acidi...

Страница 109: ...tuator 6 2 Front Differential 6 3 Drive Axles 6 16 Rear Gear Case 6 21 Hub 6 23 Hydraulic Brake Caliper 6 24 Troubleshooting Drive System 6 26 Troubleshooting Brake System 6 27 Back to TOC FOR ARCTIC...

Страница 110: ...The front drive actuator is located on the side of the front drive input housing With the engine stopped and the ignition switch in the ON position a momentary whirring sound can be heard each time th...

Страница 111: ...eating of the actuator 5 Tighten the remaining cap screws then connect the electrical plug to the main harness 6 Turn the ignition switch to the ON position and check the operation by shifting the sel...

Страница 112: ...int cap screws taking care not to strip the threads on the ball joint shaft then using a rubber mallet tap the end of the axle and free it from the knuckle assembly AF628D 11 Pull the steering knuckle...

Страница 113: ...e then remove the actuator AG925 18 Remove the lower differential mounting cap screw Account for a lock nut and washers CD026 19 Remove the upper differential mounting cap screws CD016 20 Free the dif...

Страница 114: ...bled 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing CD102 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the locat...

Страница 115: ...isting snap ring making sure the sharp edge of the snap ring faces to the outside AF993 AF994 2 Install the input shaft seal making sure it is flush with the edge of the housing 3 Lubricate the input...

Страница 116: ...being installed tighten the cap screws to 25 31 ft lb CD103 Disassembling Pinion Gear NOTE This procedure can be performed on a rear gear case 1 Using a T 40 torx wrench remove the cap screws securin...

Страница 117: ...earing flange assembly and account for a shim Mark the shim as left side KX177 KX178 6 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s a...

Страница 118: ...f the gear case housing is being replaced proceed to the following Shimming Proce dure Shim Selection sub section Shimming Procedure Shim Selection 1 Press bearings into bores by outer ring to hard co...

Страница 119: ...haft collar CC882 CC883 2 Place the pinion assembly in a bearing puller then install the bearing using a press CC884 3 Install the pinion gear assembly into the housing Using the 48 mm Internal Hex So...

Страница 120: ...shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear Install the ring gear in the housing then install the outside shim with the chamfer sid...

Страница 121: ...Removing the needle bearing is rarely necessary Avoid removing the needle bearing unless the bearing is clearly damaged NOTE This procedure can be performed on a rear gear case 1 Place a 1 4 in drill...

Страница 122: ...llar in the oil gallery area then using a hammer stake the lock collar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE Th...

Страница 123: ...ke CD857 CD859 2 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid lubricant into the differential and install the filler plug Tighten to 16 ft lb 3 Install the front drive actuator with the three torx head...

Страница 124: ...041 5 Remove the two brake calipers right side only NOTE Do not allow the brake calipers to hang from their cable hose 6 Slide the hub out of the knuckle and set aside 7 Remove the cap screw and lock...

Страница 125: ...it must be replaced with a boot kit 3 Inspect the gear case seals for nicks or damage DISASSEMBLING AXLES 1 Using a side cutters or suitable substitute remove the large clamp from the boot CD020 2 Wip...

Страница 126: ...contains 120 grams of grease The inside joint double offset requires approximately 70 90 grams of grease and the out side bell type requires approximately 35 55 grams When replacing boots use 2 3 of t...

Страница 127: ...nap ring faces away from the boot CD023 6 Making sure the marks made during disassembling align slide the housing over the bearing ring then completely seat the bearing ring into the housing and insta...

Страница 128: ...b 8 Remove the ATV from the support stand and release the brake lever lock INSTALLING FRONT DRIVE AXLE 1 Position the drive axle in the gear case and steer ing knuckle then insert the upper A arm ball...

Страница 129: ...ing 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 Remove the clutch pack from the clutch basket...

Страница 130: ...NOTE The clutch pack is not a serviceable com ponent If worn discolored or damaged in any way it must be replaced Assembling Installing 1 Install either the existing or a new bearing into the input ho...

Страница 131: ...lb 3 Install the rear drive axles see Drive Axles in this section 4 Install the left side rear A arms see Rear A Arms in Section 7 Hub REMOVING 1 Secure the ATV on a support stand to elevate the whee...

Страница 132: ...pin making sure each side of the pin is flush to the hub nut PR260 7 Install the wheel and tighten to 40 ft lb 8 Remove the ATV from the support stand Hydraulic Brake Caliper NOTE The brake calliper...

Страница 133: ...INSPECTING 1 Clean all caliper components except the brake pads with parts cleaning solvent 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Section 2 ASSEMBLIN...

Страница 134: ...roken 1 Replace shaft Problem Power not transmitted from engine to either front wheel Condition Remedy 1 Secondary drive driven gear teeth broken 2 Propeller shaft serration worn broken 3 Coupling dam...

Страница 135: ...oblem Brake lever travel excessive Condition Remedy 1 Hydraulic system entrapped air 2 Brake fluid low 3 Brake fluid incorrect 4 Piston seal cup worn 1 Bleed hydraulic system 2 Add fluid to proper lev...

Страница 136: ...TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 3 Rear A Arms 7 5 Wheels and Tires 7 7 Troubleshooting 7 8 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 56...

Страница 137: ...r 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...

Страница 138: ...e AF618D 7 Remove the cap screws securing the ball joints to the knuckle AF628D 8 Tap the ball joints out of the knuckle then remove the knuckle 9 Remove the lower shock absorber eyelet from the upper...

Страница 139: ...re with the cap screws Only fin ger tighten at this time AF610D 3 Route the brake hose through the upper A arm shock absorber mount then secure the hose to the A arm with a cable tie and grommet DE054...

Страница 140: ...nd Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex...

Страница 141: ...ve axle and into posi tion on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to 50 ft lb 3 Tighten the hardware securing the A arms to the frame mounts from...

Страница 142: ...ndicate forward direc tion of rotation AF612D CHECKING INFLATING 1 Using an air pressure gauge measure the air pres sure in each tire Adjust the air pressure as neces sary to meet the recommended infl...

Страница 143: ...t shock absorber preload Problem Suspension too stiff Condition Remedy 1 A arm related bushings worn 2 Shock absorber preload too high 1 Replace bushing 2 Adjust shock absorber preload Problem Suspens...

Страница 144: ...easuring Adjusting Toe In 8 7 Front Rack 8 8 Front Bumper Assembly 8 9 Front Body Panel Side Panels 8 9 Footrests 8 12 Belly Panel 8 13 Exhaust System 8 13 Rear Body Panel Rack 8 13 Taillight Assembly...

Страница 145: ...the cover CD666 3 Remove four reinstallable rivets securing the steering post cover and remove the cover 4 Unlatch the storage compartment lid then slide the storage compartment cover assembly forward...

Страница 146: ...two cap screws securing the lower steer ing post bearing flange to the frame then remove the steering post AL600D CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in...

Страница 147: ...new cotter pins NOTE If the slots do not align with the holes in the tie rod ends tighten the nuts just enough to allow installation of the cotter pins AF778D 4 Install the front wheels and tighten t...

Страница 148: ...ted with the smooth part of the grip facing up 3 Wipe off any excess glue then secure the grip with the handlebar end cap Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the ATV on a support sta...

Страница 149: ...h the two cap screws Tighten to 35 ft lb AF760D 3 Install the tie rod end and secure with the nut threads coated with red Loctite 271 Tighten to 30 ft lb then install a new cotter pin and spread the p...

Страница 150: ...rate measurements can occur 3 Place the ATV in a level position taking care not to push down or lift up on the front end then turn the handlebar to the straight ahead position NOTE When measuring and...

Страница 151: ...the front side then record the measurement 10 Push the ATV forward until the marks are parallel to the belly panel on the back side then measure the distance between the marks 11 The difference in th...

Страница 152: ...AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all bumper components with parts cleaning solvent 2 Inspect all welds for cracki...

Страница 153: ...grommets and bushings GZ067 6 Remove the side panels then remove the fasteners securing the rear of the front fender panel to the frame CF237A CD684A 7 Remove the left and right footwells then remove...

Страница 154: ...te the handlebar to the full left position then place the front body panel over the handlebar and rotate and lower into position CD765 2 Connect the headlight connectors to the appropri ate headlights...

Страница 155: ...to the footrests then remove the foot pegs and footwells 3 Remove the cap screws and flange nuts securing the footrests to the frame then remove the foot rests CLEANING AND INSPECTING NOTE Whenever a...

Страница 156: ...spark arrester see Section 2 INSTALLING MUFFLER 1 Place the muffler into position engaging the mounting lugs into the grommets then slide the muffler forward 2 Install the two exhaust springs Rear Bo...

Страница 157: ...osition making sure it locks securely Taillight Assembly REMOVING 1 Unplug the three prong connector and free the tail light wiring harness from the frame 2 Remove the torx head cap screws securing th...

Страница 158: ...tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bea...

Страница 159: ...TENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 3 Front Differential Lock 9 4 Shift Lever 9 4 Speedometer Tachometer LCD 9 4 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 6...

Страница 160: ...pressing it toward the pivot pin hole in the housing then lay it aside leaving the switch and wiring harness connected BC205 5 Remove the clamp screws securing the brake housing to the handlebar then...

Страница 161: ...p ring BC206 4 Bleed the brake system see Section 2 Throttle Control REMOVING 1 Remove the two machine screws securing the throttle control to the handlebar 2 Slide the grommet out of the lower half o...

Страница 162: ...NSTALLING 1 Place the spring into position between the upper shift arm and shift lever then making sure the O rings are in place on the axle secure the shift lever to the arm with the existing axle an...

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Содержание 08 ATV

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