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3. Start the engine and slowly increase RPM. The volt-

age should increase with the engine RPM to a maxi-

mum of 15.5 DC volts.



NOTE: If voltage rises above 15.5 DC volts, the regula-

tor is faulty or a battery connection is loose or corroded.
Clean and tighten battery connections or replace the
regulator/rectifier. If voltage does not rise, check Voltage
(Charging Coil - No Load) in this section. If charging coil
voltage is normal, replace the regulator/rectifier.

Lights

HEADLIGHTS - RUNNING LIGHTS

The connectors are the two 4-pin ones snapped onto the

front body/rack support. To release the connectors from

the frame, press the release tab with a small screwdriver.

KC224

KC223

Voltage (Headlights)



NOTE: Perform this test on the main harness side of

the connectors. Also, the ignition switch must be in
the LIGHTS position.

1. Set the meter selector to the DC Voltage position.

2. Connect the black tester lead to the black wire; then

connect the red tester lead to the white wire.

3. With the dimmer switch in the LO position, the

meter must show battery voltage.

4. Remove the red tester lead from the white wire and

connect to the lavender wire.

5. With the dimmer switch in the HI position, the meter

must show battery voltage.



NOTE: If battery voltage is not shown in any test,

inspect the fuses, battery, main wiring harness, con-
nectors, or the left handlebar switch.

Voltage (Running Lights)

1. Release the wire connector from the frame; then

release and separate the connectors.



NOTE: Perform this test on the wiring harness side

of the connectors.

2. Connect the black tester lead of the meter to the black

wire; then with the tester in the DC Volts position,

connect the red tester lead to the brown/black wire.

3. Turn the ignition switch to the LIGHTS position.

The meter must show battery voltage.



NOTE: If the meter does not show voltage, inspect

the LIGHTS fuse, battery connections, or trouble-
shoot the main wiring harness.

TAILLIGHTS - BRAKELIGHTS
Voltage (Taillights)



NOTE: Perform this test on the main harness side of

the connector. Also, the ignition switch should be in
the LIGHTS position.

1. Set the meter selector to the DC Voltage position.

2. Connect the black tester lead to the black wire; then

connect the red tester lead to the brown/blue wire.

3. The meter must show battery voltage.



NOTE: If the meter does not show voltage, inspect

fuses, wiring harness, connectors, and switches.

Voltage (Brakelights)



NOTE: Perform this test on the main harness side of

the connector. Also, the ignition switch should be in
the ON position and the brake (either foot pedal or
hand lever) must be applied.

1. Set the meter selector to the DC Voltage position.

2. Connect the black tester lead to the black wire; then

connect the red tester lead to the green/yellow wire.

3. The meter must show battery voltage.



NOTE: If the meter does not show voltage, inspect

bulb, fuses, wiring harness, connectors, and switches.

BACK-UP LIGHTS

The connectors are located on the rear frame supports

attached by a metal tab. They may be released from the

frame by depressing the release with a small screwdriver.

Manual

Table of Contents

Содержание 425 2011

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

Страница 2: ...Half 53 Servicing Center Crankcase Components 54 Assembling Crankcase Half 59 Joining Crankcase Halves 61 Installing Engine Transmission 62 Fuel Lubrication Cooling 64 Electronic Fuel Injection 64 Th...

Страница 3: ...max 20 021 mm Connecting Rod big end side to side max 0 7 mm Connecting Rod big end width 21 95 22 00 mm Connecting Rod small end deflection max 3 0 mm Crankshaft web to web 60 9 mm Crankshaft Runout...

Страница 4: ...rake Disc Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Brake Hose Auxiliary Brake Cylinder 20 27 Master Cylinder Rear Frame 8 11 Master Cylinder Clamp Front Master Cylinder 5 5...

Страница 5: ...5 methane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel sy...

Страница 6: ...preserver into the air filter opening for a period of 10 to 20 seconds then stop the engine Install the air filter and housing cover 4 Plug the exhaust outlet on the muffler with a clean cloth 5 Appl...

Страница 7: ...he battery then install Connect the battery cables 6 Check the entire brake systems fluid level pads etc all controls lights and headlight aim adjust or replace as necessary 7 Tighten all nuts bolts c...

Страница 8: ...er 0444 078 Item Initial Service After Break In First Mo or 100 Mi Every Day EveryMonthor 100 Miles Every 3 Months or 300 Miles Every 6 Months or 500 Miles Every Year or 1500 Miles As Needed Battery I...

Страница 9: ...then dip the element in the solvent and wash it NOTE Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat 4 Dry the element 5 Put the element in a plastic bag then pour in air...

Страница 10: ...valve tappet clearance If clearance is not within specifications loosen the jam nut and rotate the tappet adjuster screw until the clear ance is within specifications Tighten each jam nut securely aft...

Страница 11: ...the electric starter until the gauge shows a peak reading of 95 115 psi five to 10 compression strokes 6 If compression is abnormally low inspect the following items A Verify starter cranks engine ove...

Страница 12: ...the right side behind the radiator KC338B 2 Remove the cap and fill with the appropriate coolant until coolant level is between the LOW and FULL lines Do not overfill 3 Install the cap on the reservoi...

Страница 13: ...e Oil Filter Wrench and a suitable wrench remove the old oil filter NOTE Clean up any excess oil after removing the filter 7 Apply oil to a new filter seal ring and check to make sure it is positioned...

Страница 14: ...en drained install the drain plugs and tighten to 45 in lb 4 Pour the appropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole 5 Install the fill plugs and tighten to 16 ft...

Страница 15: ...ay be bent or damaged or the CDI unit ECU may be faulty Lights Rotate the ignition switch to the lights position the head lights and taillights should illuminate Test the brake lights by compressing t...

Страница 16: ...To replace the bulbs use the following procedure 1 Rotate the bulb socket counterclockwise to release from light housing then press in on the bulb and turn counterclockwise to release from the socket...

Страница 17: ...tions but the shift lever does not corre spond with the gear indicated on the LCD adjust the shift linkage To adjust proceed to ADJUSTING ADJUSTING 1 Remove the seat then remove the left side engine c...

Страница 18: ...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 procedure 4 Carefully check the entire hydraulic brake system that all hose c...

Страница 19: ...ugh 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 to 0 5 mph 3 Repeat procedure on each brak...

Страница 20: ...front of the driven pulley pull it forward and outward off the clutch shaft then remove it from the driven pulley KC136 6 Inspect the faces of the drive and driven pulleys for scoring pitting cracks...

Страница 21: ...ulleys counterclockwise until the driven pulley faces are together 5 With the two alignment pins installed in the V belt housing and a new V belt cover gasket in place install the V belt cover Using t...

Страница 22: ...ets lock nuts and seals and lubricating all internal components when servicing the engine transmis sion SPECIAL TOOLS A number of special tools must be available to the techni cian when performing ser...

Страница 23: ...defective 4 Valve clearance out of adjustment 1 Clean plug 2 Replace stator coil 3 Replace ECU 4 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excess...

Страница 24: ...hose Problem Exhaust smoke dirty or heavy Condition Remedy 1 Oil in the engine overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored scuffed 5 Valve stems wo...

Страница 25: ...each end of the exhaust pipe 8 Loosen the clamp securing the air filter housing to the front air inlet duct then disconnect the coil connector and remove the spark plug cap from the spark plug FI519A...

Страница 26: ...he thermostat housing FI530B FI537 15 Remove the cap screws securing the front and rear drivelines to the output drive flange 16 Support the engine and remove the two through bolts securing the engine...

Страница 27: ...ers Remove the two covers Account for the O rings FI603 NOTE Keep the mounting hardware with the covers for assembly purposes 2 Remove the cylinder head cover cap screws Note the rubber washers on the...

Страница 28: ...der head Account for an alignment pin NOTE Loop the chain over the cylinder and secure it to keep it from falling into the crankcase FI620 FI617A 8 Remove the cam chain tensioner pivot bolt and remove...

Страница 29: ...case half FI622A 13 Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase Account for the gasket and two alignment pins FI624A 14 Using an awl remove th...

Страница 30: ...valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Keep all valves and valve components as a set Note the original location of each va...

Страница 31: ...f the valve face FI367 2 Acceptable width must be at or above specifications Measuring Valve Face Radial Runout 1 Mount a dial indicator on the surface plate then place the valve stem on a set of V bl...

Страница 32: ...ide CC144D 2 Insert each valve into its original valve location 3 Install the valve springs with the painted end of the spring facing away from the cylinder head NOTE If the paint is not visible insta...

Страница 33: ...in outside diameter at each end and in the center If measurement exceeds specifica tions the piston pin must be replaced ATV 1070 2 Inspect and measure the connecting rod small end If the measurement...

Страница 34: ...urface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assem bly by continuing to move the cylinder head in a fig ure eight motion u...

Страница 35: ...the rate of 30 strokes per minute If honing oil is not available use a lightweight petroleum based oil Thoroughly clean cylinder after honing using soap and hot water Dry with compressed air then imme...

Страница 36: ...p screws securing the cylinder head cover to the cylinder then remove the cylinder head cover and camshaft MD1261 5 Match the width of the plasti gauge with the chart found on the plasti gauge packagi...

Страница 37: ...rs compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crankcase G...

Страница 38: ...held tight rotate the crankshaft until the piston is at top dead center 11 While holding the cam chain sprocket to the side install the rear cam chain tensioner guide into the cylinder head Install th...

Страница 39: ...cket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned 16 Place the tab washer onto the sprocket making sure it covers the pin in the alignment ho...

Страница 40: ...r arms and adjuster screws must not have pressure on them 25 Install the four top side cap screws with rubber washers then install the remaining cap screws Tighten only until snug MD1261 26 In a criss...

Страница 41: ...shers and an O ring FI544 4 Remove the water pump drive gear then remove the speed sensor housing assembly Account for two alignment pins a gasket and two seal washers FI543 5 Remove the cap screws se...

Страница 42: ...motor Account for an O ring on the starter drive housing FI555 G Shift Shaft H Drive Gear NOTE Steps 1 10 in the preceding sub sections must precede this procedure 11 Remove the shift shaft noting a...

Страница 43: ...olored rollers If bearing is damaged it must be replaced FI569 3 Inspect the one way bearing for chipped surfaces missing rollers or discoloration If any of the above conditions exist replace the star...

Страница 44: ...ure relief valve for evidence of metal chips or contamination Do not disassemble the valve FI588 REPLACING STATOR CRANKSHAFT POSITION SENSOR 1 Remove the three cap screws securing the stator coil two...

Страница 45: ...until the bearing is firmly seated in the bearing bore Installing Left Side Components A Starter Clutch Gear B Rotor Flywheel 1 If removed place the crankshaft bearing retainer into position Apply re...

Страница 46: ...to position Install the magneto cover Noting the different lengthed 6 mm cap screws and the location of the two internal cap screws tighten cap screws in a crisscross pattern to 8 ft lb FI596A 10 Inst...

Страница 47: ...ft Account for a flat washer KC149A 2 Remove the cap screws securing the V belt cover to the clutch cover then slide the brake pedal outward and remove the V belt cover Account for two align ment pins...

Страница 48: ...MD1092 9 Remove the cap screws holding the clutch cover onto the right side crankcase half Note the positions of the different lengthed cap screws for installing purposes 10 Using a rubber mallet loo...

Страница 49: ...1018 15 Remove oil pump drive gear Account for the pin MD1017 16 Remove the snap ring holding the oil pump driven gear MD1019 NOTE Always use a new snap ring when installing the oil pump driven gear 1...

Страница 50: ...for burns marks scuffs cracks scratches or uneven wear 2 If the housing is damaged in any way the housing must be replaced INSPECTING PRIMARY ONE WAY DRIVE 1 Place the one way clutch onto the clutch s...

Страница 51: ...ete assembly Installing Right Side Components A Oil Pump 1 Place two alignment pins and the oil pump into position on the crankcase and secure with the Phillips head screws coated with blue Loctite 24...

Страница 52: ...1 6 in the preceding sub section must precede this procedure 7 Install two alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 8 Tighten the clutch cover ca...

Страница 53: ...nt the cap screw can be removed from the driven pulley face 15 Rotate the V belt and drive driven assemblies until the V belt is flush with the top of the driven pulley 16 Install two alignment pins a...

Страница 54: ...semblies be kept together and in order NOTE For steps 1 6 refer to illustration FI639A FI639A 1 Remove the secondary driven shaft assembly A noting the location of the front and rear bearing locating...

Страница 55: ...ondary driven gear retaining 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...

Страница 56: ...ment is within tolerance Note the following chart Checking Tooth Contact NOTE After correcting backlash of the secondary driven bevel gear it is necessary to check tooth con tact 1 Remove the secondar...

Страница 57: ...ide of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal CC289D 3 Acceptable gap range must be within specifications Measuring Crankshaft...

Страница 58: ...r 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 dog FI668 CAU...

Страница 59: ...e 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 low shift dog 6...

Страница 60: ...ntershaft 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 make sure t...

Страница 61: ...ft 5 Install the key in the crank balancer shaft then install the gear and aligning the timing marks slide the gear into place FI658 6 Align the shift cam fork slots with the shift fork shaft locating...

Страница 62: ...g sure the front and rear bearing alignment pins are seated in the recesses then install the center carrier bearing alignment C ring FI660A FI659A FI661A Joining Crankcase Halves 1 Verify that the two...

Страница 63: ...tate the shafts back and forth to ensure no binding or sticking occurs 6 In a crisscross case to case pattern tighten the 6 mm cap screws to 10 ft lb NOTE Rotate the shafts back and forth to ensure no...

Страница 64: ...nnec tor E ISC connector F and the TPS connector G FI522A 10 Place the air filter assembly into position and con nect the crankcase breather securing with the clamp then connect the front air inlet du...

Страница 65: ...nk see Gas Tank in this section 3 Loosen the clamp securing the intake boot to the throttle body then loosen the clamp securing the intake boot to the intake housing and slide the intake housing rearw...

Страница 66: ...ove the gas tank to the rear Account for the heat shield KC260 KC262 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all...

Страница 67: ...ear of the front body to the frame with the cap screws A and tighten securely then install the gas tank cover and secure with the reinstallable rivets B KC219A 5 Install the side panels and seat makin...

Страница 68: ...ontrols section 3 Remove the upper and lower coolant hoses then remove the fill hose and air bleed hose 4 Remove the cap screws securing the radiator to the frame 5 Disconnect the fan wiring from the...

Страница 69: ...coolant hoses connections and clamps for deterioration cracks and wear NOTE All coolant hoses and clamps should be replaced every four years or 4000 miles Installing 1 Place the thermostat and O ring...

Страница 70: ...uts off Pres sure should read 3 0 kg cm2 43 psi 4 If the pump is not running disconnect the fuel pump tank sensor connector by reaching under the rear rack from behind 5 Connect a multimeter to the po...

Страница 71: ...sensor by connecting a multimeter A to the fuel level sensor leads B then select OHMS The multimeter should show 5 ohms at full fuel position C and 95 ohms at empty fuel position D ATV2116 NOTE If re...

Страница 72: ...e correct orientation to ensure adequate float lever clearance 4 Connect the wires and fuel hose then connect the negative battery cable and turn the ignition switch to the ON position Note that the f...

Страница 73: ...teries not used for more than two weeks or as required by battery drain 800E 1 When charging a battery in the vehicle be sure the ignition switch is in the OFF position 2 Clean the battery terminals w...

Страница 74: ...ons bring the battery to an autho rized Arctic Cat dealer for further troubleshooting RPM Limiter NOTE The ATV is equipped with an ECU that retards ignition timing when maximum RPM is approached When...

Страница 75: ...will occur Use wire holders to suspend the sensor and thermometer 3 On the ECT sensor when the temperature reaches 20 C 68 F the meter should read approximately 2 45k ohms 4 On the ECT sensor when the...

Страница 76: ...ge from one side of the connector terminal ends NOTE Battery voltage will be indicated from only one side of the fuse holder connector terminal the other side will show no voltage NOTE When testing th...

Страница 77: ...witch to the ON position The meter must show battery voltage Speed Sensor 1 Set the meter selector to the DC Voltage position 2 With appropriate needle adapters on the meter leads connect the red test...

Страница 78: ...the electrical cover must be removed NOTE These tests should be made on the switch side of the connector RESISTANCE HI Beam 1 Set the meter selector to the OHMS position 2 Connect one tester lead to...

Страница 79: ...osition a momentary whirring sound must be noticeable each time the selector switch is moved to 2WD and 4WD Test the switch 30 amp fuse and wiring connections prior to testing the actuator VOLTAGE 1 S...

Страница 80: ...er motor 2 Set the meter selector to the OHMS position 3 Connect the red tester lead to the green white wire then connect the black tester lead to the blue yellow wire The meter reading must be within...

Страница 81: ...move the two cap screws securing the starter to the crankcase then remove the starter Account for an O ring INSTALLING 1 Apply a small amount of grease to the O ring seal on the starter then install t...

Страница 82: ...d separate the connectors NOTE Perform this test on the wiring harness side of the connectors 2 Connect the black tester lead of the meter to the black wire then with the tester in the DC Volts positi...

Страница 83: ...leshooting other compo nents To verify engine timing see Periodic Maintenance Tilt Sensor SUPPLY VOLTAGE 1 Disconnect the three wire connector from the sensor then select DC Voltage on the multimeter...

Страница 84: ...ximately one second in the tilted position If the meter readings are not as specified the tilt sensor is defective KC414A KC416B Throttle Position Sensor TPS INSPECTING 1 Remove the left side engine c...

Страница 85: ...meter should read approximately 4 5 DC volt with the throttle closed and approximately 1 5 DC volts with the throttle in the full open position NOTE If the meter readings are as specified check the m...

Страница 86: ...ostic trouble code DTC will be generated in the ECU and displayed on the LCD For the first thirty seconds the LCD will go blank and the DTC will be displayed alternately with a wrench icon or malfunct...

Страница 87: ...gh P0485 ON K2 O L Fan Relay Control Circuit Low SG Open P0500 Gauge Direct Error Code N A N A N A Vehicle Speed Sensor P0508 ON C4 D3 D4 E4 I O V Idle Air Control System Circuit Low SG P0509 ON C4 D4...

Страница 88: ...Alternator overcharges Condition Remedy 1 Battery shorted 2 Regulator rectifier damaged defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifier 3 Clean tighten...

Страница 89: ...sound is heard see Electrical System If the actuator runs constantly or makes squeal ing or grinding sounds the actuator must be replaced REMOVING 1 Disconnect the connector on the actuator harness 2...

Страница 90: ...rential REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the drain plug and drain the gear lubricant into a drain pan then reinstall the plug and tighten to 45...

Страница 91: ...and remove the differential from the frame KC291A Disassembling Input Shaft NOTE This procedure can be performed on a rear gear case however some components may vary from model to model The technicia...

Страница 92: ...shaft seal Account for a spacer AF982 6 Remove the snap ring securing the input shaft bear ing then place the pinion housing in a press and remove the bearing AF983 AF984 KX219 Assembling Input Shaft...

Страница 93: ...ear boot with an appropriate boot clamp CD112 5 Using a new O ring lubricated with grease install the front drive actuator and secure with the cap screws 6 Place the pinion housing with new gasket ont...

Страница 94: ...79 KX181 5 Unstake the lock collar then using the 48 mm Inter nal Hex Socket remove the lock collar securing the pinion gear assembly NOTE On a front differential the lock collar has right hand thread...

Страница 95: ...eeding Backlash NOTE Always set backlash prior to any other shim ming 1 Install the existing shim or a 0 051 0 055 in shim on the gear case side of the ring gear assembly GC031A 2 Install the ring gea...

Страница 96: ...side up then install a dial indicator contacting the ring gear axle flange GC065 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008...

Страница 97: ...he chamfered side toward the ring gear then install into gear case differential housing GC031A GC059 2 Place the selected end play shim chamfered side toward the gear onto the cover side of the ring g...

Страница 98: ...needle bearing against the bottom side then drill through the pinion shaft needle bearing housing CC885 2 Using a propane torch heat the area surrounding the needle bearing to soften the Loctite CC88...

Страница 99: ...OTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool GC066 2 Using a press remove the bearing CC900 3 Using a press install the new bearing into the hous...

Страница 100: ...5 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid gear lubricant into the differential and install the filler plug Tighten to 16 ft lb 6 Remove the ATV from the support stand Drive Axles REMOVING REAR DRI...

Страница 101: ...ace the knuckle into place in the upper A arm Secure the knuckle to the A arm with a cap screw and a new lock nut Tighten to 35 ft lb 3 Place the hub into position on the axle followed by a hex nuts T...

Страница 102: ...te the wheel then remove the wheel 2 Remove the cotter pin from the nut NOTE During assembly new cotter pins should be installed 3 Remove the flange nut securing the hub 4 Remove the brake caliper KC2...

Страница 103: ...hers and a banjo fitting bolt 3 Remove the clamp screws securing the brake hous ing to the handlebar then remove the assembly from the handlebar INSPECTING NOTE Whenever a part is worn excessively cra...

Страница 104: ...e the inner brake pad NOTE If brake pads are to be returned to service do not allow brake fluid to contaminate them PR237A PR238 5 Remove the caliper holder from the caliper and dis card the O ring PR...

Страница 105: ...5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the h...

Страница 106: ...s Failure to do so will result in reduced braking and premature brake pad failure WARNING Never use brake fluid from an open container or reuse brake fluid Moisture contaminated brake fluid could caus...

Страница 107: ...rect 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 seal cup worn 1...

Страница 108: ...t be replaced INSTALLING 1 Place bushings and sleeves where appropriate into shock eyelet then install shock with cap screws and nuts Tighten all nuts to 35 ft lb 2 Remove the ATV from the support sta...

Страница 109: ...splines then install the hub assembly onto the drive axle 7 Secure the hub assembly with the nut Tighten only until snug 8 Secure the brake caliper to the knuckle with the two patch lock cap screws T...

Страница 110: ...lock nut Tighten to 35 ft lb 11 Secure the boot guard to the lower A arm with the two cap screws Tighten securely 12 Install the wheel and tighten to 40 ft lb 13 Remove the ATV from the support stand...

Страница 111: ...tires with the smallest circumference measurement until all tires are equal in circumference 6 Repeat steps 4 5 as necessary to ensure proper han dling Troubleshooting WARNING Do not operate the ATV i...

Страница 112: ...caps and move the handle bar out of the way Account for the two handlebar caps KC0058 3 Remove the cap screws securing the upper steering post to the frame Account for the housing cap outer housing an...

Страница 113: ...ousings of the upper steering post support then with the housing cap in place secure with the cap screws Tighten to 20 ft lb KC307A 3 Using red Loctite 271 on the threads install the tie rod ends into...

Страница 114: ...INSTALLING 1 Apply a liberal amount of Handlebar Grip Adhesive to the inside of the new grip 2 Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up NOT...

Страница 115: ...cable free play see Periodic Maintenance Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the wheel cap from the hu...

Страница 116: ...nd and secure with the nut Tighten to 30 ft lb then install a new cotter pin and spread the pin NOTE During assembling new cotter pins should be installed 4 Apply a small amount of grease to the hub s...

Страница 117: ...y panel AF789D 7 Measure the distance between the marks at a height parallel to the belly panel at the front side then record the measurement 8 Push the ATV forward until the marks are parallel to the...

Страница 118: ...sition and install the through bolt Start the lock nut and fin ger tighten only 2 Install the existing fasteners in the upper support tubes to frame and the front rack cap screws Tighten the lock nut...

Страница 119: ...ender panel onto the ATV With the front rack in place loosely install the front rack hardware 2 Connect the electrical connectors under the electric panel then connect the light connectors and attach...

Страница 120: ...o exhaust springs Rear Body Panel Rack REMOVING 1 Remove the rear rack then remove two cap screws securing the rear body panel fender to the side frame and the cap screws securing the rear fenders to...

Страница 121: ...all fasten ers securely KC317A KC320A 2 Connect the light connectors and secure to the frame then install the battery starter relay and auxiliary brake Connect all wiring making sure to connect the po...

Страница 122: ...nuts wheel studs 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 inflated unequa...

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