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General Information



NOTE: Some photographs and illustrations used in

this manual are used for clarity purposes only and
are not designed to depict actual conditions.



NOTE: Whenever a part is worn excessively, cracked,

or damaged in any way, replacement is necessary.

General Specifications

Specifications subject to change without notice.
* One inch below plug threads. ** At the plug threads.

Torque Specifications

* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #609 **** w/Three Bond Sealant
***** w/ “Patch-Lock”

MISCELLANY

Tire Size

(Mud Pro)
(Mud Pro)

Front - 25 x 8-12
Rear - 25 x 10-12
Front - 28 x 9-14
Rear - 28 x 11-14

Tire Inflation Pressure

0.35 kg/cm² (5 psi) - FIS/Mud
Pro
0.49 kg/cm² (7 psi) - TRV

Spark Plug Type

NGK CR7E (500)
NGK CPR8E (550/700/1000)

Spark Plug Gap

0.7-0.8 mm (0.028-0.031 in.) -
500
0.5-0.6 mm (0.019-0.024 in.) -
550/700/1000

Gas Tank Capacity

21.6 L (5.7 U.S. gal.) - FIS
21.9 L (5.8 U.S. gal.) - TBX
20.1 L (5.3 U.S. gal.) - TRV

Coolant Capacity

2.9 L (3.0 U.S. qt) -
500/550/700
3.3 L (3.5 U.S. qt) - 1000

Rear Drive Capacity

250 ml (8.5 fl oz)*

Front Differential Capacity

275 ml (9.3 fl oz)**

Engine Oil Capacity (approx)

(500)

(550/700)

(1000)

2.8 L (3.0 U.S. qt) - Overhaul
2.5 L (2.6 U.S. qt) - Change
2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
2.6 L (2.75 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

Arctic Cat ACX All Weather
(Synthetic)

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Drive Belt Width (minimum)

28.5 mm (1.12 in.) -
500/550/700
35.6 mm (1.40 in.) - 1000

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/37W (2) - 500/550/700
12V/27W (2) - 1000

ELECTRICAL SYSTEM

Ignition Timing

10° BTDC @ 1500 RPM

Spark Plug Cap

5000 ohms

Ignition Coil Resistance

(primary)

(secondary)

Less than 5.0 ohms -
500/550/700
4.8 ohms - 1000
12k-19k ohms

Ignition Coil Primary Voltage

Battery Voltage

Stator Coil (crankshaft position sensor)
Resistance

(AC generator)

150-250 ohms
Less than 1 ohm

Crankshaft Position Sensor AC Voltage 2.0 volts or more

AC Generator Output

(no load) 75 AC volts @ 5000 RPM

EXHAUST COMPONENTS

Part

Part Bolted To

Torque

ft-lb N-m

Exhaust Pipe

Engine

20

27

Spark Arrester

Muffler

48

in.-lb

5.5

ELECTRICAL COMPONENTS

Coil

Air Filter Housing

7

10

STEERING COMPONENTS

Bearing Housing

Frame

20

27

Bearing Flange

Frame

20

27

Steering Post Support

Frame

20

27

Tie Rod End

Knuckle/Steering Post

30

41

EPS Housing

Frame

35

47

BRAKE COMPONENTS

Brake Disc*

Hub

15

20

Brake Hose

Caliper/Cylinder

20

27

Master Cylinder

Frame

12

16

Caliper*****

Knuckle

20

27

CHASSIS COMPONENTS

Brake Pedal

Pedal Axle

25

34

Footrest

Frame (8 mm)

20

27

Footrest

Frame (10 mm)

40

54

SUSPENSION COMPONENTS (Front)

A-Arm Frame

50

68

Knuckle

Ball Joint

35

47

Shock Absorber

Frame/Upper A-Arm

50

68

Ball Joint

A-Arm

50

68

SUSPENSION COMPONENTS (Rear)

Shock Absorber (Upper)

Frame

50

68

Shock Absorber (Lower)

Lower A-Arm

20

27

A-Arm Frame

50

68

Knuckle

A-Arm

35

47

DRIVE TRAIN COMPONENTS

Front Differential*

Frame/Differential
Bracket

38

52

Oil Fill Plug

Front Differential/Rear
Drive

16

22

Wheel (Steel)

Hub

40

54

Wheel (Aluminum)

Hub

80

108

Rear Gear Case*

Frame

38

52

Hub

Shaft/Axle

200

272

Oil Drain Plug

Front Differential/Rear
Drive

45

in.-lb

5

Pinion Housing

Differential Housing

23

31

Differential Housing Cover***

Differential Housing

23

31

Input Shaft Assembly

Differential Housing

23

31

Thrust Button**

Gear Case Cover

8

11

Input Shaft/Housing

Gear Case

23

31

Output Shaft**

Rear Gear Case Flange

20

27

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Содержание 1000 Cruiser

Страница 1: ...500 550 700 1000 MUD PRO TRV ATV SERVICE MANUAL 2014...

Страница 2: ...s to be completed The technician should use sound judgement when determining which proce dures can be completed based on their skill level and access to appropriate special tools All Arctic Cat ATV pu...

Страница 3: ...ne 1000 135 Installing Engine Transmission 1000 180 Fuel Lubrication Cooling 183 Electronic Fuel Injection 183 Throttle Cable Free Play 185 Engine RPM Idle 186 Gas Tank 186 Oil Filter Oil Pump 186 Tes...

Страница 4: ...ICAL SYSTEM Ignition Timing 10 BTDC 1500 RPM Spark Plug Cap 5000 ohms Ignition Coil Resistance primary secondary Less than 5 0 ohms 500 550 700 4 8 ohms 1000 12k 19k ohms Ignition Coil Primary Voltage...

Страница 5: ...rame Bracket 35 47 ENGINE TRANSMISSION 500 Oil Pump Drive Gear Crankshaft 63 85 Cam Chain Tensioner Guide Cylinder Head 11 15 Cam Chain Tensioner Cylinder 10 14 Water Pump Drive Gear Crankshaft 28 38...

Страница 6: ...on Preparation For Storage Arctic Cat recommends the following procedure to pre pare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the ATV t...

Страница 7: ...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 lev...

Страница 8: ...er 0444 255 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 Ever...

Страница 9: ...TE Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat 5 Squeeze the element by pressing it between the palms of both hands to remove excess solvent Do not twist or wring the...

Страница 10: ...over assembly compartment box air filter filter housing and left side right side splash panels must be removed for this procedure A Place Valve Clearance Adjuster onto the jam nut securing the tappet...

Страница 11: ...e cannot be run cold values are included 5 While holding the throttle lever in the full open posi tion crank the engine over with the electric starter until the gauge shows a peak reading five to 10 c...

Страница 12: ...assembly to the muffler then loosen and remove the arrester CF105A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket...

Страница 13: ...tor can reduce cooling capability Using a garden hose wash the radiator to remove any debris preventing air flow The cooling system capacity can be found in General Information The cooling system shou...

Страница 14: ...76 2 On the 700 1000 models lift the front of the access panel then slide the panel forward to disengage the two rear tabs 3 On the 700 1000 models move the panel rearward until free of the rack On th...

Страница 15: ...te amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole NOTE If the differential rear drive lubricant is con taminated with water inspect the drain plug fill plug and or bladder 6...

Страница 16: ...DJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizon tally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the ATV...

Страница 17: ...ition switch and LCD connector Hydraulic Brake Systems CHECKING BLEEDING The hydraulic brake systems have been filled and bled at the factory To check and or bleed a hydraulic brake sys tem use the fo...

Страница 18: ...e on the brake pedal open the bleeder screw and watch for air bubbles Close the bleeder screw before releasing the brake pedal Repeat this proce dure until no air bubbles are present AF637D PR377C NOT...

Страница 19: ...owing procedure 1 Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate...

Страница 20: ...appropriate spanner wrench tighten the nut to 147 ft lb 500 model or 165 ft lb 550 700 1000 models GZ485A NOTE At this point the CVT cover cap screw can be removed 3 With the vehicle in neutral rotat...

Страница 21: ...19 CD083 5 Install the right side footrest see Steer ing Frame Controls 6 Secure the front fender to the footrest with the two cap screws Tighten securely...

Страница 22: ...me welds and racks should be checked periodi cally for damage bends cracks deterioration broken components and missing components Front Body Panel Side Panels REMOVING 1 Remove the reinstallable rivet...

Страница 23: ...s from the body then remove the screws securing the rear of the front panel to the frame CF237A FI470A 7 Remove the left and right footwells then remove the shift knob Remove the shift lever pivot axl...

Страница 24: ...ate headlights and the front accessory plug wires to the accessory plug CD681 3 Make sure the rubber grommets and bushings are in place then place the front rack into position and secure with the cap...

Страница 25: ...the footwells CD691A 3 Remove two machine screws securing the battery cover and remove the cover CD687A 4 Disconnect the battery negative cable first then remove the battery 5 Disconnect the taillight...

Страница 26: ...NOTE If the front body panel has not been installed see Front Body Panel Side Panels in this section 6 Place the seat into position making sure it locks securely LCD Gauge REPLACING 1 Remove the two...

Страница 27: ...f the way Account for four handlebar caps CD762 7 Remove two cap screws securing the upper steering post bearing to the frame Account for two housings CD760 8 Using a suitable lift stand raise the ATV...

Страница 28: ...4 Inspect all welded areas for cracks or deterioration 5 Inspect the steering post and steering post brackets for cracks bends or wear 6 Inspect the bearing halves bearing caps and bearing housings fo...

Страница 29: ...into position on the steering post then position the LCD gauge on top of the caps and secure with the four cap screws Tighten securely 6 Install the storage compartment box then attach the storage com...

Страница 30: ...TE 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 EPS005A 4 Connect the 2 pin and 8 pin connectors to the EPS...

Страница 31: ...y seated with the smooth part of the grip facing up 3 Wipe off any excess glue then secure the grip with the handlebar end cap Throttle Control REMOVING 1 Remove the two machine screws securing the th...

Страница 32: ...ove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then...

Страница 33: ...mbly onto the splines of the shaft 6 Secure the hub assembly with the nut Tighten only until snug PR257 7 Secure the brake caliper to the knuckle with new patch lock cap screws Tighten to 20 ft lb PR2...

Страница 34: ...ed acces sories 4 Measure the distance from the outside edge of each handlebar grip to equal reference points on each DE047A 5 Adjust the handlebar direction until the two measure ments are equal then...

Страница 35: ...gle 733 559A Shift Lever REMOVING 1 Remove the E clip securing the shift rod to the shift lever 2 Remove two cap screws two self tapping screws and three nylon ties securing the left side splash panel...

Страница 36: ...ng the foot pegs 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 footrests CLEANING AND INSPECTING...

Страница 37: ...ALLING 1 Place the assembly into position on the frame and secure with torx head cap screws and any washers 2 Tighten the cap screws securely 3 Route the wiring harness over the rear frame then connec...

Страница 38: ...ge box securing the box to the footrest 4 Remove the screw securing the box to the side panel 5 Remove cap screws A and B securing the box to the frame CD045A CLEANING AND INSPECTING 1 Clean all side...

Страница 39: ...r 2 Inspect the cargo box for cracks tears and loose mounting hardware 3 Inspect the welds of the cargo box frame for cracking or bending 4 Inspect the cargo box gate latches for smooth opera tion INS...

Страница 40: ...ighten replace cap screws 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflate...

Страница 41: ...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...

Страница 42: ...ft web to web 60 8 60 9 mm Crankshaft Runout max 0 03 mm VALVES AND GUIDES Valve Face Diameter max intake exhaust 31 6 mm 27 9 mm Valve Tappet Clearance intake cold engine max exhaust 0 1016 mm 0 1524...

Страница 43: ...lve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Replace ECM 4 Replace fuel injector 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance...

Страница 44: ...ion Remedy 1 Engine oil overfilled 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 replace oil 2 Repla...

Страница 45: ...mp securing the air filter housing to the front air inlet duct then disconnect the coil con nector and remove the spark plug cap from the spark plug FI519A 8 Disconnect the crankcase breather hose fro...

Страница 46: ...ws securing the exhaust pipe to the engine then remove the springs securing the muffler to the exhaust pipe 13 Remove the muffler and exhaust pipe Account for a grafoil seal on each end of the exhaust...

Страница 47: ...er Head Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appropriate wrench rotate the crankshaft to top dead center o...

Страница 48: ...n into the crankcase MD1131 6 Noting the timing marks for installing purposes drop the sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cyl inder head A...

Страница 49: ...he cylinder remove the gasket and account for two alignment pins FI623A 10 Remove the cam chain guide FI621 C Cylinder D Piston NOTE Steps 1 10 in the preceding sub section must precede this procedure...

Страница 50: ...s valve faces and valve stem ends for pits burn marks or other signs of abnormal wear NOTE Whenever a valve is out of tolerance it must be replaced Cleaning Inspecting Cylinder Head Cover NOTE If the...

Страница 51: ...s Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC134D CC136D NOTE The valve seals must be replaced 3 Remove the valve...

Страница 52: ...g or replacement Arctic Cat recommends that the compo nents be taken to a qualified machine shop for servicing Measuring Rocker Arm Inside Diameter 1 Using a dial calipers measure the inside diameter...

Страница 53: ...working it toward the top of the piston while rotating it out of the groove NOTE When installing new rings install as a complete set only Cleaning Inspecting Piston Ring Grooves 1 Take an old piston...

Страница 54: ...ander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap...

Страница 55: ...move the cylinder in a figure eight motion until a uniform bright metallic finish is attained CC129D Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks or chips 2 If the chain...

Страница 56: ...1 Inspect the bearing journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder...

Страница 57: ...cted the unloader pin should be round side out CF060A 2 If damaged the camshaft must be replaced Installing Top Side Components A Piston B Cylinder 1 Lubricate the piston pin connecting rod and piston...

Страница 58: ...e the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity MD1347 7 Install the four cylinder head cap screws with wash ers Note that the two cap sc...

Страница 59: ...n in the camshaft aligns with the smallest hole in the sprocket 13 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the camshaft lobes onto...

Страница 60: ...der head plug with the cupped end facing the camshaft and the opening directed down wards 21 Place the cam chain tensioner assembly and gasket into the cylinder Tighten to 10 ft lb 22 Using a flat bla...

Страница 61: ...cian 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 Water Pump B Speed Sensor C Mag...

Страница 62: ...rter Clutch Gear F Starter Motor NOTE Steps 1 6 in the preceding sub section must precede this procedure 7 Remove the nut securing the rotor flywheel on the crankshaft and install the crankshaft prote...

Страница 63: ...at the hub flange is directed toward the crankcase FI564 FI566 Servicing Left Side Components INSPECTING STARTER CLUTCH GEAR 1 Place the starter clutch gear onto the rotor flywheel and attempt to rota...

Страница 64: ...6 ft lb using a crisscross pattern Make sure the one way bearing is installed with the notches directed away from the rotor flywheel FI576A FI578 REPLACING STARTER GEAR BEARING 1 Support the starter c...

Страница 65: ...ensor FI590 3 Install the new stator coil assembly and secure with three cap screws Tighten to 15 ft lb 4 Place the stator wire harness hold down into posi tion then install the crankshaft position se...

Страница 66: ...ft assembly and washer mak ing sure to align the alignment marks FI559 6 Install starter idler gears 1 and 2 FI555A 7 Install the starter clutch gear onto the crankshaft then install the rotor flywhee...

Страница 67: ...emove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does no...

Страница 68: ...fixed drive face for installing purposes then remove the nut holding the movable drive face onto the crankshaft MD1033 4 Remove the movable drive face and spacer Account for the movable drive face rol...

Страница 69: ...alling pur poses 10 Using a rubber mallet loosen the clutch cover then pull it away from the right side crankcase half Account for two alignment pins and gasket MD1115 D Centrifugal Clutch Assembly E...

Страница 70: ...snap ring when install ing the oil pump driven gear 17 Remove oil pump driven gear Account for the drive pin and thrust washer MD1020 G Oil Pump Oil Strainer NOTE Steps 1 17 in the preceding sub sect...

Страница 71: ...ng is damaged in any way the housing must be replaced INSPECTING PRIMARY ONE WAY DRIVE 1 Place the one way clutch onto the clutch shoe assem bly with the green dot or the word OUTSIDE directed away fr...

Страница 72: ...Phillips head screws securely MD1337 2 Place the strainer cap into position on the crankcase making sure the O ring is properly installed and secure with the four cap screws Tighten the cap screws to...

Страница 73: ...s the clutch shoe 8 Install the one way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase MD1286 B Clutch Cover C Fixed Drive Face D Movable Drive Face NOTE...

Страница 74: ...until the faces open sufficiently to allow the V belt to drop into the pulley approximately 3 4 in KC137 NOTE The arrows on the V belt should point in direction of engine rotation 15 Making sure the m...

Страница 75: ...Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those com...

Страница 76: ...y A noting the location of the front and rear bearing locating pins and the center bearing locating ring FI660A FI659A FI661A 2 Remove the reverse idler assembly B Account for and note the location of...

Страница 77: ...taining nut From inside the crankcase using a rubber mallet drive out the output shaft assembly Account for the output shaft a shim a washer and the nut Servicing Center Crankcase Components SECONDARY...

Страница 78: ...rement is within tolerance Note the following chart Checking Tooth Contact NOTE After correcting backlash of the second ary driven bevel gear it is necessary to check tooth contact 1 Remove the second...

Страница 79: ...suring Connecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and cranks...

Страница 80: ...gear washer then remove the low driven gear along with the bearing and bushing FI666 FI667 4 Remove the splined washer then remove the circlip securing the high low sliding dog Remove the slid ing do...

Страница 81: ...asher 1 on the countershaft install the high driven gear bushing 3 bearings 2 and gear 4 on the countershaft then install the washers 5 and secure with the snap ring FI671A FI670 2 Install the high lo...

Страница 82: ...NOTE The countershaft assembly is now ready to be installed Assembling Crankcase Half NOTE For ease of assembly install components on the right side crankcase half NOTE If the output shaft was removed...

Страница 83: ...te the crankshaft so the counterweight is toward the rear of the engine Install the crank balancer shaft MD1024 5 Install the key in the crank balancer shaft then install the gear and aligning the tim...

Страница 84: ...FI653A FI655A 9 Install the input driveshaft FI646 10 Install the spacer 1 shaft 2 reverse idler gear and washer 3 FI641A FI645 11 Install the secondary output driveshaft assembly into the crankcase...

Страница 85: ...ghtening the cap screws MD1008 4 From the left side install the remaining crankcase cap screws then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occur...

Страница 86: ...starter motor and tighten securely FI534A 8 Connect the engine ground wire to the starter mount ing flange and secure with a cap screw tightened to 8 ft lb 9 From the top side install the ECT sensor c...

Страница 87: ...beneath the engine transmission then drain the coolant 733 441A CD799A 7 Remove the air filter see Periodic Maintenance 8 Remove the gasline hose connector from the fuel rail FI092E 9 Loosen the clam...

Страница 88: ...the throttle body assembly up and away from the engine 14 Remove the E clip securing the shift rod to the engine shift arm then allow the shift rod to swing forward and hang straight down from the shi...

Страница 89: ...he sen sor housing CD794 21 On the right side disconnect the stator coil and crankshaft position sensor connectors 22 Disconnect the temperature sensor lead from the wir ing harness CD788 23 Remove th...

Страница 90: ...ne 550 700 Top Side Components 88 Removing Top Side Components 89 Servicing Top Side Components 92 Installing Top Side Components 99 Left Side Components 104 Removing Left Side Components 104 Servicin...

Страница 91: ...ap screws next to the spark plug These will keep the alignment pins in place Note the two rubber washers on the remaining cap screws H1 013A 4 Remove the valve cover Account for and note the orientati...

Страница 92: ...haft out of the cylinder head NOTE Loop the chain over the cylinder and secure it to keep it from falling into the crankcase FI620 9 Remove the cap screw securing the chain tensioner account for a was...

Страница 93: ...he hose 14 Remove the two nuts securing the cylinder to the crankcase CC023D 15 Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase Account for the ga...

Страница 94: ...t be trued the cylin der head assembly must be replaced 1 Wash the valve cover in parts cleaning solvent 2 Place the valve cover on the Surface Plate covered with 400 grit wet or dry sandpaper Using l...

Страница 95: ...ring Valve Stem Runout 1 Support each valve stem end with the V Blocks then check the valve stem runout using a dial indicator ATV 1082 2 Maximum runout must not exceed specifications Measuring Valve...

Страница 96: ...r valve seats require servicing or replacement Arctic Cat recommends that the compo nents be taken to a qualified machine shop for servicing Measuring Rocker Arm Inside Diameter 1 Using a dial caliper...

Страница 97: ...e top ring slide one end of the ring out of the ring groove CC400D 2 Remove each ring by working it toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will no...

Страница 98: ...ton pin bore Subtract this measure ment from the measurement in step 1 The difference clearance must not exceed specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of...

Страница 99: ...actor between the head and the straightedge 3 Maximum distortion must not exceed specifications CC141D Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder...

Страница 100: ...honing using soap and hot water Dry with compressed air then immediately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder CC390D 4 If any measurement exce...

Страница 101: ...ine camshaft to cylinder head and valve cover clearance CC145D 6 If clearance is excessive measure the journals of the camshaft CC287D NOTE If the journals are worn replace the cam shaft then measure...

Страница 102: ...lin der to the crankcase NOTE The two cylinder to crankcase nuts will be tightened in step 11 CC023D 5 Install the coolant hose onto the crankcase union and tighten the clamp C Cylinder Head D Valve C...

Страница 103: ...rfaces on the cylinder 14 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the cam shaft lobes onto the camshaft At this point do not seat...

Страница 104: ...nstalled then install the cap screw threads coated with red Loctite 271 and tighten to 10 ft lb Bend the tab to secure the cap screw CD465 20 Rotate the crankshaft until the first cap screw from step...

Страница 105: ...adjuster assembly and gas ket into position on the cylinder and secure with the two cap screws CD469 25 Using a flat blade screwdriver rotate the adjuster screw inside the tensioner counterclockwise u...

Страница 106: ...on does not have to be removed from the frame for this procedure Removing Left Side Components A Outer Magneto Cover B Water Pump C Cover D Rotor Flywheel 1 Remove the four cap screws securing the out...

Страница 107: ...ller remove the side cover Account for a gasket and two alignment pins 9 Remove the nut securing the magneto rotor to the crankshaft then install the magneto rotor puller adapter NOTE The puller has l...

Страница 108: ...purposes Account for two washers PR430A 15 Remove the gear shift cam plate and account for a washer then remove the cam stopper and cam stop per spring Account for two washers PR434A Servicing Left S...

Страница 109: ...he notches directed away from the rotor flywheel FI576A FI578 REPLACING STARTER GEAR BEARING 1 Support the starter clutch gear in a press making sure to support the hub around the entire circumference...

Страница 110: ...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 w...

Страница 111: ...he two starter gears with the beveled side of the intermedi ate gear facing inward as noted in removing CD139 PR447A 4 In order on the crankshaft install a washer ring gear key and the magneto rotor S...

Страница 112: ...ngine oil then place it into position on the two alignment pins Make sure the outer shift shaft washer is in place PR431A 9 Install the magneto cover and secure with the cap screws Tighten only until...

Страница 113: ...E For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgmen...

Страница 114: ...29B NOTE To aid in installing it is recommended that the assemblies are kept together and IN ORDER CC829B 7 Remove the one way clutch D from the clutch housing Note the location of the green alignment...

Страница 115: ...10 Remove the nut left hand threads securing the clutch shoe assembly C PR410A 11 Remove the cap screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer CC606 CD987 CD9...

Страница 116: ...t the clutch shoes for wear or damage If any shoe is worn to the bottom of the groove replace the clutch assembly ATV1014 INSPECTING CLUTCH HOUSING 1 Inspect the clutch housing for burns grooving crac...

Страница 117: ...9 3 Install the oil pump onto the engine then tighten the screws coated with red Loctite 271 to 8 ft lb CD988 4 Install the oil pump drive gear spacer onto the crank balancer shaft Grease the pin and...

Страница 118: ...lutch onto the clutch shoe assembly PR399A 9 Lightly grease the clutch housing seal then insert the left fixed drive spacer CF088A CF085A 10 Apply grease to the outer edges of the clutch hous ing then...

Страница 119: ...until the V belt drops into the driven pulley 1 2 to 3 4 inch CF270A H1 020A 16 Place the V belt into position on the driven pulley and over the front shaft PR389 NOTE The arrows on the V belt should...

Страница 120: ...ts The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the right side cap screws securing the crankcase halves Note the location of the differ ent lengthed cap...

Страница 121: ...a spacer and a washer DE677A 5 Remove the countershaft assembly D Account for a washer on each end of the countershaft CC674 NOTE Do not disassemble the countershaft assem bly unless necessary If nec...

Страница 122: ...ut driven shaft is replaced or disassembled the initial set up must be performed to establish correct gear tooth contact If only the secondary output drive shaft or secondary output driven gear is rep...

Страница 123: ...ing Backlash 1 If removed install the secondary drive bevel gear shaft into the crankcase then tighten the nut to 59 ft lb 2 Install the secondary drive bearing support then install the secondary driv...

Страница 124: ...nd 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 Measuring Connecting Rod Big End Side to...

Страница 125: ...nap ring securing the reverse driven gear dog and bushing to the countershaft GZ296 GZ312 3 Remove the reverse driven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer...

Страница 126: ...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 G...

Страница 127: ...er 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...

Страница 128: ...e CC688 CC689 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft install ing tool 3 Install the crank balancer CD832B NOTE It will be necessary to rotate th...

Страница 129: ...of the crankcase and the bearing C ring is fully seated in the crankcase PR787B 11 Place the oil strainer into position then secure with the two screws 12 Place the oil strainer cap into position mak...

Страница 130: ...the engine transmission into the frame then slide the engine rearward as far as possible 2 Slightly raise the rear of the engine and engage the front drive coupler into the splines of the front drive...

Страница 131: ...the main wir ing harness 11 Secure the wires to the frame with nylon ties 12 Connect the speed sensor connector to the housing 13 Secure the positive cable to the starter motor 14 Secure all wiring t...

Страница 132: ...into position in the battery compart ment then install the battery cables and vent hose Secure with the battery cover 23 Add proper amounts of engine transmission oil and coolant 24 Install the seat...

Страница 133: ...uel rails GZ124 5 Disconnect the TPS connector A MAP sensor con nector B and ISC valve connector C from the throttle body then route the harness and connectors away from the engine GZ094A NOTE Using a...

Страница 134: ...posi tion switch connector from the gear position switch GZ069A GZ493A 9 Loosen the clamps securing the V belt cooling ducts to the V belt housing then disconnect the cooling ducts GZ037 GZ103B 10 Rem...

Страница 135: ...linder GZ099A 14 Remove the front and rear spark plug wires from the spark plugs then disconnect the primary wire con nectors from the coils and remove the coils from the left side of the frame GZ071A...

Страница 136: ...in plug and tighten securely GZ009A 19 Remove the coolant hoses from the upper engine coolant outlet pipes then remove the lower coolant hose from the water pump GZ028 GZ369A GZ008 20 Remove the flang...

Страница 137: ...ents 163 Center Crankcase Components 166 Separating Crankcase Halves 166 Disassembling Crankcase Half 167 Servicing Center Crankcase Components 169 Assembling Crankcase Half 176 Joining Crankcase Halv...

Страница 138: ...t the two top side cap screws next to the spark plug These will keep the alignment pins in place Note the two rubber washers on the remaining cap screws 5 Remove the valve cover Account for and note t...

Страница 139: ...pin into the engine GZ154A 9 While holding the chain slide the sprocket and cam shaft out of the cylinder head CC266D NOTE Loop the chain over the cylinder head and secure it to keep it from falling i...

Страница 140: ...e cap screws securing the water hose union to the cylinder then remove the union from the cylinder Account for an O ring GZ140A 14 Remove the two nuts securing the cylinder to the crankcase GZ141A GZ1...

Страница 141: ...00 grit wet or dry sandpaper Using light pressure move the valve cover in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metall...

Страница 142: ...cks then check the valve stem runout using a dial indicator ATV 1082 2 Maximum runout must not exceed specifications Measuring Valve Stem Outside Diameter 1 Using a micrometer measure the valve stem o...

Страница 143: ...seats require servicing or replacement Arctic Cat recommends the components be taken to a qualified machine shop for servicing Measuring Rocker Arm Inside Diameter 1 Using a dial calipers measure the...

Страница 144: ...he 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 blowby ind...

Страница 145: ...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 compressi...

Страница 146: ...linder in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assembly by continu ing...

Страница 147: ...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...

Страница 148: ...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...

Страница 149: ...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 GZ1...

Страница 150: ...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 thi...

Страница 151: ...nstall 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 tight...

Страница 152: ...ad 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 t...

Страница 153: ...1 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...

Страница 154: ...t 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 be...

Страница 155: ...d 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 procedur...

Страница 156: ...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 flywhee...

Страница 157: ...uring 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 t...

Страница 158: ...heel 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...

Страница 159: ...secure with three cap screws using a drop of red Loctite 271 on each Tighten according to the chart 4 Place the stator wire harness hold down into posi tion then install the crankshaft position senso...

Страница 160: ...ift 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 T...

Страница 161: ...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 1...

Страница 162: ...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...

Страница 163: ...gnment pins GZ246A 7 Remove the cap screws securing the clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pins GZ246B 8 Using a suitable press remove the clu...

Страница 164: ...TING CENTRIFUGAL CLUTCH SHOES 1 Inspect the clutch shoes for wear chips cracks dam age or discoloration If any shoe is damaged replace the centrifugal clutch INSPECTING CLUTCH HOUSING 1 Inspect the cl...

Страница 165: ...r pump drive cover and secure with the snap ring flat side away from the bearing GZ441 2 Install the gear onto the driveshaft noting correct ori entation from step 1 of disassembling GZ442 3 Install t...

Страница 166: ...e screws threads coated with blue Loctite 242 Tighten to 8 ft lb GZ508 7 Press the clutch housing assembly into the clutch cover until it is seated against the bearing GZ512 8 Install a new O ring int...

Страница 167: ...e face onto the clutch shaft 13 Spread the faces of the driven clutch by threading in a cap screw then when the faces are separated insert the belt and push down between the faces GZ065A 14 Place the...

Страница 168: ...install the water pump drive housing cover and tighten the cap screws to 8 ft lb GZ437A Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Comple...

Страница 169: ...ed If disassembled second ary gear sets will have to be reset for backlash and gear contact see Servicing Center Crankcase Com ponents sub section 4 Remove one cap screw from the right side crankcase...

Страница 170: ...en remove the drive idler GZ299A 3 Remove the snap ring securing the water pump idler shaft C in the crankcase then remove the shaft and bearings GZ463A 4 Remove the snap ring securing the oil pump dr...

Страница 171: ...establish correct gear tooth contact If only the secondary output driveshaft or secondary output driven gear are replaced proceed to Correct ing Backlash in this sub section 1 Install a new bearing A...

Страница 172: ...klash in this sub section Checking Backlash 1 Install the drive bevel gear assembly and driven bevel gear output shaft assembly into the crankcase bottom cover 2 Mount the dial indicator so the tip is...

Страница 173: ...ssembling and Inspecting 1 Remove the oil pump cover then remove the gerotor set shaft and pin see Disassembling Crankcase Half in this sub section 2 Inspect the crankcase for scoring discoloration or...

Страница 174: ...et separate the inner rotor from the outer rotor and with the ref erence dot directed toward the oil pump cover place the rotor on the shaft then install the drive pin and push the shaft into the roto...

Страница 175: ...ting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal...

Страница 176: ...3 Remove the reverse driven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer then remove the washer and gear GZ314 5 Remove the reverse driven washer then remove the...

Страница 177: ...ng then install the low driven gear and washer GZ317A GZ318 2 Install the low driven gear locking washer then install the inner reverse driven gear washer GZ319B GZ320B 3 Install the reverse driven bu...

Страница 178: ...d the shift forks The countershaft is now ready for installation Assembling Crankcase Half 1 Install the oil pump gerotor assembly and oil pump cover into the crankcase and secure with two cap screws...

Страница 179: ...Z474 NOTE It will be necessary to rotate the crankshaft back and forth to engage the teeth of the oil pump and countershaft gears 6 Install the driveshaft then with a flat washer on each end of the re...

Страница 180: ...the radius directed toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of Loctite 5900 or suitable substitute sealant to the crankcase mating surface NOTE Apply sealan...

Страница 181: ...backlash 6 Install the locating ring in the crankcase assembly then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly...

Страница 182: ...GZ110A GZ119 4 Align the rear output shaft and the rear gear case flange and install the cap screws coated with red Loctite 271 Tighten to 20 ft lb 5 Align the engine with the mounting brackets and in...

Страница 183: ...connect all exhaust junc ture springs GZ099A GZ372 11 Install the intake manifolds and tighten to 8 ft lb then install the throttle body and secure with the hose clamps GZ106 GZ107 GZ090B 12 Connect...

Страница 184: ...ts Tighten securely 17 Install the front body panel footrests foot wells and front rack then install the upper bumper sup port to frame cap screws see Steering Frame Con trols 18 Connect the negative...

Страница 185: ...switch key 2 Remove the seat then disconnect the battery 3 Remove the storage compartment cover and air filter housing cover then remove the air filter 4 Loosen the clamp securing the air filter hous...

Страница 186: ...throttle arm cover and disconnect the throttle cable then remove the throttle body from the ATV GZ383A 6 Use tape to cover and seal the intake opening INSTALLING 500 550 700 1 Install the throttle bo...

Страница 187: ...e to the throttle body then remove the tape from the intake manifold and install the throttle body using a new O ring Tighten the cap screws securely GZ381A 2 Connect the three wiring connectors to th...

Страница 188: ...up assembly 2 Place the gas tank into position in the frame then install the cap screws Tighten securely 3 Connect the gasline hose from the throttle body then connect the fuel gauge connector 4 Fill...

Страница 189: ...to their respective fittings and secure with the clamps Liquid Cooling System When filling the cooling system use premixed Arctic Cat Antifreeze While the cooling system is being filled air pockets ma...

Страница 190: ...to the cylinder head Account for an O ring and a thermostat Removing 1000 NOTE The thermostat is located in a housing in line with the upper radiator hoses under the air fil ter housing GZ036A 1 Drai...

Страница 191: ...ced as an assembly Removing 1 Remove the radiator cap then remove the water pump drain and drain the coolant CC789 2 Drain the oil from the engine transmission 3 Remove the four torx head cap screws s...

Страница 192: ...00 NOTE The water pump is a non serviceable compo nent It must be replaced as an assembly Removing 1 Remove the coolant drain plug then remove the radia tor cap and drain the coolant into a suitable c...

Страница 193: ...dicated and the fuel pump does not run replace the pump assembly If no bat tery voltage is indicated check the ECM and the vehicle tilt sensor REMOVING 1 Remove the rear rack and fenders see Steer ing...

Страница 194: ...n ing then carefully guide the fuel pump into position taking care not to damage the float or float lever KX190 3 Rotate the fuel pump until the match marks align then install the mounting screws and...

Страница 195: ...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 330...

Страница 196: ...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 reach...

Страница 197: ...2 3 When the brake pedal is depressed the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance replace the switch Brakelight Switch Handlebar Control To access the co...

Страница 198: ...dings are not as indicated the sensor must be replaced 8 Install the sensor and tighten securely 9 Connect the leads Fan Motor The connector is the black two prong one located above the oil cooler rad...

Страница 199: ...and wiring harness are not a service able components and must be replaced as an assembly Ignition Coil NOTE On the 1000 models the following proce dures should be performed on both ignition coils The...

Страница 200: ...rom the pressure sensor located on top of the throttle body 2 Select DC Voltage on the tester and turn the ignition switch to the ON position 3 Connect the black tester lead to the black green wire an...

Страница 201: ...5 Leave the black tester lead connected then connect the red tester lead to the signal lead S pin 6 Slowly move the ATV forward or backward the meter must show 0 and 6 12 DC volts alternately NOTE If...

Страница 202: ...dropped below 500 RPM Handlebar switch in the OFF position bro ken main harness RPM wires defect voltage regulator broken ACG stator wires EPS will auto recover when engine RPM signal returns to norm...

Страница 203: ...th the ignition switch to the ON posi tion the meter must read more than 8 5 DC volts if correct voltage is not present check connections and wiring harness if correct voltage is present replace EPS a...

Страница 204: ...to the LIGHTS position 6 Connect either tester lead to pin A then connect the other tester lead to pin B 7 The meter must show less than 1 ohm 8 Connect either tester lead to pin C then connect the o...

Страница 205: ...and front fenders must be removed see Steering Frame Con trols 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to one red yellow wire then connect the black tester wire to...

Страница 206: ...8 Select Differential Lock on the drive select switch then connect the red tester lead to the white orange wire in the supply harness The meter must show 0 DC volts 9 Connect the tester lead to the wh...

Страница 207: ...switch in the RUN position 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 mo...

Страница 208: ...The regulator rectifier is located under the rear rack and rear fenders TESTING 1 Start engine and warm up to normal operating tem perature then connect a multimeter to the battery as follows 2 Selec...

Страница 209: ...ignition timing can aid in troubleshooting other components To verify ignition timing use the following procedure 1 Attach the Timing Light to the spark plug high ten sion lead then remove the timing...

Страница 210: ...on If the meter readings are not as specified the tilt sensor is defective CD709 NOTE When replacing the sensor after testing make sure the arrow marking is directed up CD705A Throttle Position Sensor...

Страница 211: ...nd the three pin plug on the TPS for contamination bro ken pins and or corrosion NOTE If the vehicle is in warranty removing or adjusting the TPS will void warranty If the TPS is tested out of specifi...

Страница 212: ...both Mode and Set buttons together for approximately 10 seconds after which the letters dIAg will appear on the LCD momen tarily followed by COOL EFI002A NOTE The display on the gauge will display in...

Страница 213: ...B fan relay C fan fuse D wiring connections 5 High Temperature Rev Limiter 5000 RPM 230 F Fuel Sensor FUEL Diagnostic Mode EFI010 Display Fuel level signal from the fuel level sensor measured in ohms...

Страница 214: ...in Hg Inches of Mercury 34 millibars are equal to 1 inch of mercury Example Gauge reading in the BARO mode 974 millibars thus 974 34 28 64 in Hg Second example Local barometer reading is 29 87 in Hg t...

Страница 215: ...orted to chassis ground Correct condition P0123 TPS Circuit High Sensor or interconnect harness open or shorted to battery power Correct condition P0130 O2 Sensor Intermittent Open Sensor or interconn...

Страница 216: ...n starter relay or interconnect harness intermittent or shorted to chassis ground Correct condition P0617 Starter Relay Circuit High Start switch button starter relay or interconnect harness intermitt...

Страница 217: ...fier 4 Replace battery Problem Battery overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier resistor damaged defective 3 Regulator rectifier poorly grounded 1 Replace...

Страница 218: ...ed REMOVING 1 Disconnect the connector on the actuator harness 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the actuator AG926 3 Remove the mounting cap screw f...

Страница 219: ...ct switch several times 7 Secure the wiring harness to the frame with a nylon cable tie Front Differential REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the...

Страница 220: ...bber mallet tap the end of the axle and free it from the knuckle assembly AF628D 11 Pull the steering knuckle away from the axle KX151 12 Support the axle to not allow it to drop or hang 13 Remove the...

Страница 221: ...uator to the gear case 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...

Страница 222: ...Remove the fork collar and spring Note the location of all the components for assem bling purposes GC015 CD106 3 Using a boot clamp pliers or suitable substitute remove the boot clamps then remove th...

Страница 223: ...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 Secure with new clamps...

Страница 224: ...ring 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 p...

Страница 225: ...he 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 bea...

Страница 226: ...ery impor tant to properly adjust any gear set prior to final assem bly The following procedure can be used on both front differ ential or rear drive gear case NOTE All bearings must be installed in t...

Страница 227: ...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 g...

Страница 228: ...ith the cover side up then install a dial indicator contacting the ring gear axle flange GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should b...

Страница 229: ...fferential housing cover assembly install the cover with existing cap screws coated with green Loctite 609 Account for the ID tag Tighten the cap screws evenly to 23 ft lb NOTE Grease can be applied t...

Страница 230: ...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 coated with blue Lo...

Страница 231: ...ith the lock nuts Tighten to 30 ft lb then install and spread the cotter pins AF896D AF895D 9 Install the brake calipers and secure with new patch lock cap screws tightened to 20 ft lb AF894D 10 Insta...

Страница 232: ...holding the axle in pull the CV cup from the gear case NOTE Keeping the axle level will aid in removal PR729C REMOVING FRONT DRIVE AXLE NOTE For removing a front drive axle see Front Differential in t...

Страница 233: ...NOTE In the outboard boot use the final 40 grams 1 3 of contents of grease from the pack in the bear ing housing INSTALLING REAR DRIVE AXLE 1 Push the axle shaft into the CV cup to release the detent...

Страница 234: ...tall and spread a new cotter pin 4 Slide the hub w brake disc into position in the steer ing knuckle followed by a washer and hex nut Tighten finger tight at this time 5 Install the brake caliper on t...

Страница 235: ...shim for the thrust button 1 Install the thrust button with shim into the gear case cover and tighten securely left hand threads GC057A 2 Place the ring gear with selected shim into the cover and mea...

Страница 236: ...taining the input bearing and using an appropriate bearing driver press the bearing from the housing GZ184A Cleaning and Inspecting 1 Wash all parts in parts cleaning solvent and dry with compressed a...

Страница 237: ...irected outward then install the clutch pack into the basket GZ176 5 Using a new gasket install the assembled input shaft housing onto the rear drive gear case and secure with the three cap screws Tig...

Страница 238: ...ake disc to the hub with the four cap screws coated with blue Loctite 243 Tighten to 15 ft lb 2 Apply grease to the splines in the hub 3 Install the hub assembly onto the shaft PR290 4 Secure the hub...

Страница 239: ...light switch from the master cyl inder housing by gently 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...

Страница 240: ...opened container Brake fluid readily absorbs moisture from the air signifi cantly lowering the boiling point This increases the chance of vapor lock reducing braking power and increasing stopping dist...

Страница 241: ...ke caliper housing then remove four O rings from the brake caliper housing noting the location of the different sized O rings Discard all seals O rings and crush wash ers CLEANING AND INSPECTING 1 Cle...

Страница 242: ...liper PR719C 4 Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented NOTE It is very important to apply silicone grease to the O rings and caliper bores...

Страница 243: ...sion during hard braking resulting in greatly increased stopping distance or loss of control leading to injury or death Problem Power not transmitted from engine to wheels Condition Remedy 1 Rear axle...

Страница 244: ...ic system correct or repair leaks 5 Replace master cylinder Problem Brake lever travel excessive Condition Remedy 1 Hydraulic system entrapped air 2 Brake fluid low 3 Brake fluid incorrect 4 Piston se...

Страница 245: ...ch front shock absorber to the frame and the upper A arm Account for bushings and sleeves from each AF605D 3 Remove the two cap screws and nut securing each rear shock absorber to the frame and lower...

Страница 246: ...OTE Do not allow the brake caliper to hang from the cable hose 5 Remove the hub assembly 6 Remove the cotter pin and slotted nut securing the tie rod end to the knuckle then remove the tie rod end fro...

Страница 247: ...F616D 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 th...

Страница 248: ...ighten to 40 ft lb steel wheels or 80 ft lb aluminum wheels 14 Remove the ATV from the support stand Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand b...

Страница 249: ...Tighten to 35 ft lb 3 Tighten the hardware securing the A arms to the frame from step 1 to 50 ft lb 4 Apply grease on the drive axle splines then install the hub assembly onto the drive axle PR290 5...

Страница 250: ...e rotation arrow if applicable must indicate forward direction of rotation AF612D CHECKING INFLATING 1 Using an air pressure gauge measure the air pressure in each tire Adjust the air pressure as nece...

Страница 251: ...ition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Auxiliary brake adjusted incorrectly 6 Rear suspension arm related bu...

Страница 252: ...250 NOTES...

Страница 253: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 841...

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