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2. Compress the reservoir clamp and remove the reser-

voir hose; then remove the union bolt. Account for

and discard two crush washers.

KM801A

3. Remove the cotter pin from the clevis pin and

remove the clevis pin; then remove the two cap

screws securing the master cylinder to the frame and

remove the master cylinder.

KM801B

4. Loosen the jam nut; then remove the clevis and

adjuster nut.

INSTALLING

1. Install the jam nut; then install the clevis and adjuster

nut. Finger-tighten only at this time.

2. Secure the master cylinder to the frame with the two

cap screws and tighten securely.

3. Using two new crush washers, connect the brake

hose to the master cylinder with the union bolt; then

making sure the spring clamp is seated securely, con-

nect the reservoir hose to the master cylinder.

Tighten the union bolt to 25 ft-lb.

4. Making sure the brake pedal is fully released and

against the stop, turn the clevis and adjuster nut until

the hole in the clevis is aligned with the hole in the

brake pedal lever; then tighten the jam nut securely.

CD476

KM801C

5. Fill the master cylinder reservoir with DOT 4 brake

fluid and bleed the system (see Periodic Mainte-

nance/Tune-Up - Hydraulic Brake Systems).

Содержание Altera 300

Страница 1: ...2017 S SERVICE ERVICE MANUAL ANUAL www arcticcat com ...

Страница 2: ...ervicing Left Side Components 42 Installing Left Side Components 48 Right Side Components 49 Removing Right Side Components 49 Servicing Right Side Components 53 Installing Right Side Components 58 Center Crankcase Components 59 Separating Crankcase Halves 59 Disassembling Crankcase Half 59 Servicing Center Crankcase Components 59 Assembling Crankcase Half 60 Joining Crankcase Halves 61 Installing...

Страница 3: ...an to certain and specific procedures to promote effi ciency and to improve clarity At the time of publication all information photographs and illustrations were technically correct Some photo graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Arctic Cat Inc constantly refines and improves its products no retroactive obligation is...

Страница 4: ...25 34 BRAKE COMPONENTS Part Part Bolted To Torque ft lb N m Brake Hose Union Bolt Master Cylinder Caliper 25 34 Brake Bleed Screw Caliper 56 in lb 6 Brake Caliper Mounting Cap Screw Steering Knuckle Swing Arm 25 34 Master Cylinder Front Handlebar 13 18 Brake Pad Mounting Pin Front Rear Brake Caliper 13 18 Brake Caliper Slide Pin Front Rear Brake Caliper 25 34 Front Brake Line Nut Brake Line Juncti...

Страница 5: ...ft lb N m ft lb N m ft lb N m ft lb N m 1 1 4 26 35 4 51 69 4 76 103 4 2 2 7 27 36 7 52 70 7 77 104 7 3 4 1 28 38 1 53 72 1 78 106 1 4 5 4 29 39 4 54 73 4 79 107 4 5 6 8 30 40 8 55 74 8 80 108 8 6 8 2 31 42 2 56 76 2 81 110 2 7 9 5 32 43 5 57 77 5 82 111 5 8 10 9 33 44 9 58 78 9 83 112 9 9 12 2 34 46 2 59 80 2 84 114 2 10 13 6 35 47 6 60 81 6 85 115 6 11 15 36 49 61 83 86 117 12 16 3 37 50 3 62 84...

Страница 6: ... 3 Check all control wires and cables for signs of wear or fraying Replace if necessary 4 Change the engine oil and filter 5 Check the coolant level and add properly mixed coolant as necessary 6 Charge the battery then install Connect the battery cables 7 Check the entire brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace as necessar...

Страница 7: ...n in the chart below and capitalized NOTE Special tools are available from the Arctic Cat Service Parts Department Air Filter Use the following procedure to remove the filter and inspect and or clean it CLEANING AND INSPECTING FILTER 1 Remove the seat 2 Remove the air filter housing cover from the retain ing clips KM095A 3 Remove the air filter retaining cap screw 1 then remove the foam elements 2...

Страница 8: ...er onto the jam nut securing the tappet adjuster screw then rotate the adjuster dial clockwise until the end is seated in the tappet adjuster screw 4 While holding the adjuster dial in place use the adjuster handle and loosen the jam nut then rotate the tappet adjuster screw clockwise until friction is felt 5 Align the adjuster handle with one of the marks on the adjuster dial 6 While holding the ...

Страница 9: ... fuel ratio are correct A white or dark insulator indi cates that the engine may need to be serviced or the car buretor may need to be adjusted To maintain a hot strong spark keep the plug free of carbon ATV 0051 Adjust the gap to 0 8 0 9 mm 0 032 0 036 in for proper ignition Use a wire feeler gauge to check the gap ATV0052B A new spark plug should be tightened 1 2 turn once the washer contacts th...

Страница 10: ...and tighten to 11 ft lb 7 Install the oil drain plug and tighten to 11 ft lb 8 Remove the oil fill plug and pour in 1 6 L 1 7 U S qt of the recommended oil into the fill hole then install the oil fill plug 9 Start the engine while the ATV is outside on level ground and allow it to idle for a few minutes 10 Turn the engine off and wait approximately one min ute Check the oil level in the engine oil...

Страница 11: ... guard and tighten the cap screws securely 6 Pour the appropriate amount of recommended lubri cant into the fill hole Remove the level plug and check for appropriate level 7 Install the fill plug Transmission Lubricant Change the lubricant according to the Periodic Mainte nance Chart When changing the lubricant use approved SAE 80W 90 hypoid gear lube To change the lubricant use the following proc...

Страница 12: ...he factory 1 With the master cylinder in a level position check the fluid level in the reservoir If the level in the res ervoir is not visible in the sight glass add DOT 4 brake fluid XA074 2 Compress the brake lever pedal several times to check for a firm brake If the brake is not firm the system must be bled 3 To bleed the brake system use the following proce dure A Remove the cover and fill the...

Страница 13: ...s as follows 1 Remove a front wheel 2 Measure the thickness of each brake pad 3 If thickness of either brake pad is less than 1 0 mm 0 039 in the brake pad must be replaced NOTE The brake pads should be replaced as a set 4 To replace the brake pads use the following proce dure A With the wheel removed remove the brake pad alignment pins from the caliper then remove the mounting cap screws KM265A K...

Страница 14: ...iper holder and remove the brake pads KM267 Inspecting and Measuring 1 Inspect the pads for gouges chips or wear 2 Inspect the disc for gouges grooves cracks and warpage 3 Using a calipers measure the thickness of each brake pad 4 If the thickness of either brake pad is less than 1 0 mm 0 039 in the brake pad must be replaced NOTE The brake pads should be replaced as a set Installing 1 Install new...

Страница 15: ...ap screws securing the V belt cover noting the location of the different lengthed cap screws for installing purposes then using a rubber mallet gently tap on the cover tabs to loosen the cover Remove the cover Account for two alignment pins and one gasket KM253 4 Remove the nut securing the movable drive face then remove the face Account for the stepped washer and spacer KM276 5 Remove the nut sec...

Страница 16: ...r should sit over the splines KM263A 4 Secure the movable drive face to the crankshaft with the drive pulley nut and tighten to 72 ft lb 5 Install the V belt cover and tighten the cap screws securely then connect the cooling boots and tighten the clamps securely 6 Install the recoil starter and footwell assembly Tighten all hardware securely CAUTION If the splines are not protruding as shown the V...

Страница 17: ...ly for damage bends cracks deterioration broken components and missing components Front Rack Body Panel Fender REMOVING 1 Remove the seat 2 Release both headlight connectors from the frame then disconnect the headlight connectors from the main harness NOTE Use a small screwdriver to disengage the tab connector allowing the connector assembly to be removed from the frame KC223 3 Remove the Phillips...

Страница 18: ...o the gas tank XA065A XA066 8 Remove the two self tapping screws securing the inlet of the CVT intake tube to the front body panel XA067 9 From within the front fascia remove the two cap screws securing the fascia to the front bumper From the front of the vehicle remove the two cap screws securing the front of the fascia to the bumper XA068A XA070 10 Remove the Allen head screw securing the shift ...

Страница 19: ...ift lever using the Allen head screw Secure the CVT intake tube using the two machine screws Connect each headlight connector then secure the connectors to the frame via the locking tabs XA072 4 Secure the front body panel to the gas tank then install both footwells XA066 XA064A 5 Install the gas tank cover making sure the locating tabs properly align with and engage the front body panel Secure th...

Страница 20: ... XA083A CLEANING AND INSPECTING 1 Clean the fascia and related components with soap and water 2 Inspect the fascia and fenders for cracks 3 Inspect threaded areas of all mounting studs for strip ping 4 Inspect for missing decals INSTALLING 1 Place the front fascia into the front body panel and secure it using the five cap screws in the locations shown From the front of the fascia install and secur...

Страница 21: ... pry against the PDM locking tab D to release the PDM from the rear body panel XA076A XA078A 3 Remove the six cap screws securing the front body panel to the frame and gas tank Pull the front body panel out and away from the frame XA077A 4 Remove the self tapping screws securing the rear over mold to the rear rack then remove the four cap screws securing the rear rack to the frame Remove the rack ...

Страница 22: ...e the two halves of the CVT outlet tubes together with the clamp 2 With the four steel inserts installed into each rubber grommet place the rear rack into position and secure with the four cap screws 3 Place the rear over mold atop the rear rack and secure it using the self tapping screws XA080A 4 Install the six cap screws securing the front body panel to the frame gas tank and rear body panel th...

Страница 23: ...t a serviceable component To inspect the LCD gauge see Electrical System INSTALLING 1 Connect the main harness connector to the LCD gauge then connect the ignition harness to the igni tion connectors 2 Place the instrument pod onto the mounting bracket then secure with the reinstallable rivet and two cap screws Steering Post Tie Rods REMOVING 1 Remove the steering post cover 2 Remove the instrumen...

Страница 24: ...ect the handlebar grips for damage or wear 9 Inspect the lower steering post support bearing and seal for wear or cracks INSTALLING 1 Apply a thin coat of grease to the lips of the lower steering post seals then lower the steering post into position in the lower steering post bearings KM593 2 Apply a thin coat of grease to the upper steering post bushing then secure the steering post with the sup ...

Страница 25: ...d at the correct angle NOTE The front wheels do not have to be removed to adjust the tie rod Also care should be taken not to disturb the handlebar position Throttle Control REMOVING 1 Remove the boot from the throttle cable adjuster then loosen the jam nut and turn the adjuster com pletely in to loosen the cable 2 Remove the three machine screws securing the cover to the throttle control then rem...

Страница 26: ...d swing the spring clip away from the bulb then remove the bulb from the housing XA058A 3 Install the new bulb into the housing then secure with the spring clip XA058 4 Connect the three wire connector to the bulb then install the rubber boot To replace the front running light bulbs use the follow ing procedure Rotate the bulb socket counterclockwise to remove from the headlight housing account fo...

Страница 27: ...l s 3 Tighten 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 inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair repl...

Страница 28: ...er operation during this break in period will help assure maximum life and performance from the ATV Instruct the customer to follow the proper break in procedure as described in the Operators Manual SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appro priate tool desc...

Страница 29: ...magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replace camshaft Problem Engine noisy Noise seems to come from piston Condition Remedy 1 Piston cylinder worn 2...

Страница 30: ...nition coil 9 Adjust float height 10 Clean jets 11 Adjust pilot screw Problem Engine runs poorly at high speed Condition Remedy 1 High RPM cut out against RPM limiter 2 Valve springs weak 3 Valve timing out of adjustment 4 Cams rocker arms worn 5 Spark plug gap too narrow 6 Ignition coil defective 7 Float level too low 8 Air cleaner element obstructed 9 Fuel hose obstructed 1 Shift into higher gea...

Страница 31: ...fold leaking air 8 Coolant level low 9 Fan malfunctioning 10 Fan switch malfunctioning 11 Thermostat stuck closed 12 Radiator hoses cap damaged obstructed 1 Clean piston 2 Add oil 3 Drain replace gasoline 4 Replace pump 5 Clean circuit 6 Adjust float height 7 Tighten replace manifold 8 Fill examine system for leaks 9 Check fan fuse replace fan 10 Replace fan switch 11 Replace thermostat 12 Clear o...

Страница 32: ...tank see Fuel Lubrication Cooling 6 Remove the muffler assembly see Steer ing Body Controls 7 Remove the carburetor see Fuel Lubrication Cool ing 8 Remove the ignition coil see Electrical System 9 From the right side of the frame disconnect the sta tor connector gear position connector trigger coil connector and coolant temperature sensor KM347B KM324A 10 Remove the starter positive wire then remo...

Страница 33: ...Attach a suitable lifting sling and engine lift to the front engine mounting boss then using an engine lift apply slight upward pressure on the engine transmission KM332A 16 Remove the upper rear and lower rear engine through bolts to free the engine transmission then raise the front of the engine transmission sufficiently to allow the engine assembly to be moved forward enough to disengage the dr...

Страница 34: ... inspec tion plug then rotate the crankshaft to top dead cen ter of the compression stroke 1 On the right side remove the air intake hose from the cylinder head cover Retain the hose clamp KM941A 2 Remove the vent hose from the top of the cylinder head cover Retain the hose clamp 3 Remove the cap screws and nuts securing the air pipe to the cylinder head cover KM937A KM939A 4 Remove the cap screws...

Страница 35: ...e the cylin der head Account for two alignment pins and a cyl inder head gasket KM718A 9 Remove the cam chain guide then disconnect the coolant hose and remove the cylinder Support the piston with rubber bands or other suitable supports Account for two dowel pins and the cylinder gasket KM450 C Cylinder D Piston NOTE Steps 1 6 in the preceding sub section must precede this procedure 10 Using a nee...

Страница 36: ...ng Camshaft Holder 1 Remove the rocker arm shafts rocker arms and stop plate from the camshaft holder KM708A 2 Inspect the camshaft holder for cracks distortion or galling 3 Inspect the rocker arm shafts for blue discoloration or scoring 4 Inspect the rocker arms for excessive wear loose adjusters or scored camshaft followers KM710A Removing Valves NOTE Keep all valves and valve components as a se...

Страница 37: ...der Head Distortion 1 Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion factor between the head and the straightedge 3 Maximum distortion must not exceed specifications CC141D Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe height ATV1013A 2 The lobe heights must not be less than ...

Страница 38: ...toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will not be replaced with new ones note the location of each ring for proper installation When installing new rings install as a complete set only Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cyl inder Use the piston to position each ring squarely in the cylin...

Страница 39: ...ed Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting scoring scuffing warpage and corrosion If marks are found repair the surface using a surface plate 3 Place the cylinder on the surface plate covered with 400 grit wet or dry sandpaper Using light pressure move the cylinder in a figure eight motion Inspect the sealing surface for any ind...

Страница 40: ...e tensioner spring KM705 C Cylinder Head D Valve Cover NOTE Steps 1 4 in the preceding sub section must precede this procedure 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder 6 Place the head gasket into position on the cylinder Place the alignment pins into position then place the head assembly into position on the cylinder making sure the cam chain is r...

Страница 41: ... sioner screw counterclockwise to tension the cam chain KM705 11 Install the cam chain tensioner cover bolt and tighten to 24 in lb 12 Check that the cam gear alignment marks are cor rectly oriented then install and tighten the external cylinder head to cylinder cap screws to 7 ft lb 13 Install the cylinder head cover with a new O ring and tighten securely KM703 14 Install the air pipe and vent ho...

Страница 42: ... preceding sub section must precede this procedure 2 Remove the ten cap screws securing the V belt cover then remove the cover noting the location of the two dowel pins Note the condition of the V belt cover gasket Replace if damaged KM253 3 Using a suitable holder to prevent the drive pulley from turning remove the drive face nut and starter ratchet then remove the drive pulley face KM365 4 Hold ...

Страница 43: ...from the starter handle and pull the rope out of the handle then untie the knot in the rope and remove the handle Account for a flat washer KM408 NOTE Do not remove the spiral spring unless replacement is necessary It should be visually inspected in place to save time If replacement is nec essary follow steps 6 7 6 Remove the spiral spring from the case by lifting the spring end up and out Hold th...

Страница 44: ...until the complete spring is installed NOTE The spiral spring must seat evenly in the recoil case KM402 2 Insert the rope through the hole in the reel and tie a knot in the end then wrap the rope clockwise around the reel leaving approximately 50 cm 20 in of rope free of the reel 3 Apply low temperature grease to the spring and hub 4 Thread the end of the rope through the guide hole of the case th...

Страница 45: ...aring for excessive wear rough or binding when turning seal condition and secure mounting in the V belt cover NOTE If the bearing is worn excessively turns roughly or bearing seals are loose the bearings must be replaced KM254 2 Inspect the V belt cover for cracks distortion and loose alignment pins NOTE If the V belt cover is cracked or distorted or if the bearing is loose in the cover the cover ...

Страница 46: ...he spring com pressor then remove the drive plate nut KM373 3 Release the spring pressure and remove the centrifu gal clutch assembly from the driven pulley KM375 4 Remove the spring and spring seat then remove the hub collar KM385 5 Remove four pins and bushings from the fixed face hub then remove the movable face KM384 KM380 WARNING This procedure involves relaxing a compressed spring assembly D...

Страница 47: ...h If the free length is less than 131 mm the spring must be replaced KM376 6 Measure the driven fixed face hub using a calipers The minimum service limit is 39 93 mm KM378 7 Measure the thickness of the centrifugal clutch shoe lining The minimum service limit for the lining is 0 5 mm NOTE If any shoe lining is below the service limit the complete set must be replaced Assembling 1 Place the fixed f...

Страница 48: ...rease KM384 4 Install the spring seat over the hub and movable face hub KM385 5 Place the spring holder on the spring then install the spring on the pulley assembly KM386 6 Place the centrifugal clutch assembly drive plate nut and clutch compressor adapter in position then using the clutch compressor wing nut compress the clutch spring and install the nut lightly coated with red Loctite 271 KM373 ...

Страница 49: ...y faces then install the driven pulley centrifugal clutch assembly onto the driveshaft Loop the V belt over the drive pulley col lar KM262 KM369 4 Place the fixed drive face into position on the crank shaft and engage the splines making sure the splines extend beyond the pulley face hub KM263A 5 Install the starter ratchet on the crankshaft making sure to engage the splines then secure with the fl...

Страница 50: ...table con tainer then install the drain plug A and tighten to 21 ft lb KM954B NOTE If the engine has not been removed remove the swing arm assembly see Drive System Rear Drive Axle REMOVING 2 Using a crisscross pattern remove four cap screws securing the secondary driven bevel gear assembly to the transmission case cover then remove the assem bly Account for an O ring KM646A 3 Remove the three cap...

Страница 51: ...en removed see Removing Left Side Components in this section Remove only the V belt cover 6 Remove the eight cap screws securing the transmis sion case cover to the transmission case then remove the cover Account for a gasket A the secondary drive bevel gear washer B and two alignment pins C KM651A KM652A 7 Remove the shift shaft then remove plug seal washer spring and shift cam stopper ball KM677...

Страница 52: ...4 B Remove the high drive gear circlip and washer then remove the high drive gear and thrust washer KM685 12 To disassemble the driveshaft use the following pro cedure A Remove the thrust washer then remove the reverse gear KM689A B Remove a thrust washer and the low reverse clutch dog KM690A C Remove the low driven gear snap ring and washer then remove the low driven gear and thrust washer ...

Страница 53: ...wheel 14 Remove the right crankcase cover see Fuel Lubrica tion Cooling Water Pump 15 Remove the trigger coil mounting screws then remove the wire set plate KM772A 16 Remove the three cap screws securing the stator coil to the crankcase cover then remove the stator coil and trigger coil 17 Remove the oil through and spring from the end of the crankshaft then hold the rotor flywheel with an appropr...

Страница 54: ... cap screws securing the oil baffle to the crankcase and remove the baffle then remove the snap ring securing the oil pump driven sprocket KM428 KM429 22 Remove the oil pump drive chain and oil pump driven sprocket 23 Remove the two cap screws securing the oil pump to the crankcase and remove the oil pump Servicing Right Side Components TRANSMISSION Inspecting 1 Measure the shift fork guide shaft ...

Страница 55: ... indicator so as to allow the tip to con tact the secondary driven bevel gear 3 Mount the indicator tip of the dial indicator on the secondary driven bevel gear centered on the gear tooth 4 While rocking the driven bevel gear back and forth note the maximum backlash reading on the gauge 5 Acceptable backlash range is 0 03 0 15 mm 0 001 0 006 in Correcting Backlash NOTE If backlash measurement is w...

Страница 56: ...ease or decrease shims as necessary on both secondary drive and driven gears equally Use the Tooth Con tact Shim Correction chart above for shim selec tions Assembling 1 Using the appropriate bearing and seal drivers install any required bearings and seals in the trans mission case and case cover KM696 2 Replace any required bearings and seals in the sec ondary driven bevel gear shaft case Apply o...

Страница 57: ...5A 7 Install the high gear clutch dog and flat washer At this point the countershaft is ready for installation KM684 8 Install the low driven gear washer on the driveshaft then install the low driven gear and thrust washer Secure with a snap ring KM692A 9 Install the low reverse clutch dog and spacer washer then install the reverse gear and reverse gear thrust washer At this point the driveshaft i...

Страница 58: ...M619A 14 Install the shift shaft making sure to align the timing mark between the two marks on the shift cam KM702A 15 Install the two alignment pins gasket and transmis sion case cover and secure with eight cap screws Tighten in a crisscross pattern to 20 ft lb KM651A 16 Install a spacer washer and the drive bevel gear on the driveshaft then while holding the centrifugal clutch housing with an ap...

Страница 59: ...ll the starter idler shaft and gear in the crank case then install the starter driven gear on the crank shaft KM767 NOTE Make sure the crankshaft and rotor fly wheel contact surfaces are clean and dry before installing the flywheel 5 Install the key in the crankshaft then with the starter one way bearing correctly installed place the rotor flywheel onto the crankshaft and position the aligning key...

Страница 60: ...pins and a gasket Disassembling Crankcase Half 1 Remove the crankshaft from the left crankcase half KM721 2 Remove the balancer shaft from the left crankcase half KM722 Servicing Center Crankcase Components CRANKSHAFT ASSEMBLY Measuring Connecting Rod Small End Inside Diameter 1 Insert a snap gauge into the upper connecting rod small end bore then remove the gauge and measure it with micrometer CC...

Страница 61: ...he crankshaft by positioning the indicator contact at point 2 and following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the out side edge of one web to the outside edge of the other web ATV 1017 2 Acceptable width range must be within specifica tions CRANK BALANCER SHAFT Inspecting Inspect the gear teeth and bearing surfaces for chips dis coloration or ex...

Страница 62: ... halves are correctly joined then tighten to 8 ft lb NOTE Rotate the crankshaft back and forth to ensure no binding or sticking occurs Installing Engine Transmission 1 Attach a suitable engine lift to the front engine mounting boss then lift the engine transmission assembly into the frame from the left side The front of the engine transmission should go in first KM331 2 Lifting the front of the en...

Страница 63: ...rdware Tighten securely KM319A 11 Connect the coolant temperature sensor then con nect the trigger coil connector shift position connec tor and stator connector KM324A KM347A 12 Install the ignition coil see Electrical System 13 Install the carburetor see Fuel Lubrication Cooling 14 Install the muffler assembly see Steering Body Con trols 15 Install the gas tank and air filter see Fuel Lubrica tio...

Страница 64: ...ter off its mount KM959 4 Remove the choke assembly from the carburetor leaving the choke cable attached to the choke plunger KC0018 5 Remove the screw securing the throttle actuator cover to the carburetor then remove the cover PR154B 6 Remove the throttle cable from the actuator arm PR162C 7 Loosen the outer jam nut securing the throttle cable to the carburetor body then route the cable out of t...

Страница 65: ...rom the carbu retor body Account for a spring spring seat and the jet needle KC0021A 3 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring KC0022A KC0063A 4 Remove the float pin KC0024A 5 Lift the float assembly from the carburetor Account for the float valve CC753 NOTE Note the locations of the jets and holder for disassembling procedures CC76...

Страница 66: ...s obstructed the mixture will be extremely lean at idle and part throttle operation 11 Inspect the float valve for wear or damage 12 Inspect the carburetor mounting flange for damage and tightness ASSEMBLING NOTE Note the locations of the jets and holder during assembling procedures CC761B 1 Install the slow jet Tighten securely 2 Install the main jet into the needle jet holder and tighten securel...

Страница 67: ... PR162C 4 Place the throttle actuator cover into position on the carburetor then secure with the screw PR154B 5 Connect the choke assembly to the carburetor 6 Position and install the gas tank valve to the gas tank mount and secure Install the fuel inlet hose to the carburetor KM959 7 Tighten the clamp securing the air inlet boot to the carburetor Secure the air filter housing to the frame with th...

Страница 68: ...of 1250 1350 RPM Gas Tank REMOVING 1 Turn the gas tank valve to the OFF position 2 Remove the seat then remove the steering post cover and gas tank cover 3 Remove the six cap screws securing the front body panel assembly to the frame and gas tank XA077A 4 Clamp and pinch off the fuel inlet hose to the carbu retor Remove the two fasteners securing the gas tank valve to the gas tank mount Slide the ...

Страница 69: ... tank to the carburetor In this position 4 54 L 1 2 U S gal will remain in the tank as a reserve quantity Moving the valve to the RES position will allow the operator to use the remaining gasoline in the tank When turning the valve to any of the three positions make sure the indica tor is pointed directly at the position desired REMOVING INSPECTING 1 Remove the gas hoses from the valve by releasin...

Страница 70: ... at the engine KM314A 2 Remove the front rack then remove the front cover and fender assembly see Steering Body Controls Front Rack Body Panel Fender 3 Remove the upper and lower coolant hoses 4 Remove the cap screws and nuts securing the radia tor to the frame 5 Disconnect the fan wiring from the main wiring har ness then remove the radiator fan assembly and account for the grommets and collars 6...

Страница 71: ...stat housing with the two cap screws Tighten securely 2 Fill the cooling system with the recommended amount of antifreeze Check for leakage Fan REMOVING 1 Remove the radiator 2 Remove the fan assembly from the radiator INSTALLING 1 Position the fan assembly on the radiator then secure with existing hardware 2 Install the radiator Water Pump REMOVING DISASSEMBLING 1 Drain the coolant 2 Remove the f...

Страница 72: ...ondition Remedy 1 Slow jet obstructed loose 2 Slow jet outlet obstructed 3 Low speed fuel screw setting incorrect 4 Starter valve not fully closed 5 Float height incorrect 1 Clean tighten jet 2 Clean outlet 3 Adjust screw 4 Adjust valve 5 Adjust float height Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 2 Main jet obstructed 3 Needle jet obstructed 4...

Страница 73: ...rge may be caused by ambient tem perature ignition OFF current draw corroded terminals self discharge frequent start stops and short engine run times Frequent winch usage snow plowing extended low RPM operation short trips and high amperage accessory usage are also reasons for battery discharge Charging Maintenance Charging NOTE Arctic Cat recommends the use of the CTEK Multi US 800 for charging o...

Страница 74: ...y voltage trou bleshoot the battery 30 amp fuse or the main wiring harness RESISTANCE NOTE Perform this test on the upper side of the connector 1 Turn the ignition switch to the ON position 2 Set the meter selector to the OHMS position 3 Connect the red tester lead to the red wire then con nect the black tester lead to the black wire 4 The meter must show less than 1 ohm 5 Turn the ignition switch...

Страница 75: ...o the brown blue wire then connect the black tester lead to ground 3 The meter must show battery voltage NOTE If the meter shows no battery voltage trou bleshoot the battery fuse switch or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good proceed to test the switch component the connector and the switch wir ing harness for resistance RESISTANCE Handleb...

Страница 76: ...this test in turn on the main har ness side of the connectors Also the ignition switch must be in the LIGHTS position and the engine must be running 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the green wire then connect the black tester lead to the white wire 3 With the dimmer switch in the LO position LO beam the meter must show battery voltage 4 Connect ...

Страница 77: ... rectifier is replaced TESTING 1 Start the engine and warm up to normal operating temperature then connect a multimeter to the battery as follows 2 Select the DC Voltage position then connect the red tester lead to the positive battery post and the black tester lead to the negative battery post 3 Start the engine and slowly increase RPM The volt age should increase with the engine RPM to a maxi mu...

Страница 78: ...n switch when the temperature reaches 86 90 C 187 194 F the meter should read a closed circuit On the coolant temperature sen sor when the temperature reaches 120 C 218 F the meter should read 16 0 ohms 4 Allow the oil to cool On the cooling fan switch when the temperature is within a range of 80 85 C 176 185 F the meter should read an open circuit On the coolant temperature sensor monitor the tem...

Страница 79: ...r connector terminals individually 5 The meter must show battery voltage from one side of the connector terminal ends 6 Install the 30 amp fuse then using the red tester lead check the remaining two fuse holder connectors as in step 4 NOTE Battery voltage will be indicated from only one side of the fuse holder connector terminal the other side will show no voltage NOTE If the meter shows no batter...

Страница 80: ...black wire The tester must read battery voltage and the speed ometer backlight 5 must illuminate If the tester does not read battery voltage troubleshoot the igni tion switch or wiring harness connectors 11 Depress and hold the Mode Set button 1 The speedometer should switch between mph and km h as indicated by icon 12 12 Depress and hold the Mode Set button 2 The dis tance mode should shift betwe...

Страница 81: ...em Magneto overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifier 3 Clean tighten ground connection Problem Charging unstable Condition Remedy 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier defective 1 Replace lead wire 2 Replace mag...

Страница 82: ... then remove the rear brake calipers and brake disc NOTE Do not apply the brakes with the calipers removed The brake pistons will be pushed out and brake fluid will be spilled KM505 5 Remove the rear drive gear case then drain the gear case 6 Loosen the clamp securing the joint boot to the swing arm then slip the boot off the swing arm KM504 7 Remove the clamp securing the brakeline hose to the sw...

Страница 83: ...n using a rubber mallet drive the axle shaft from the swing arm tube Account for two O rings KM536 KM537 14 Place the right end shorter length of the axle on a wood block then using a rubber mallet drive the gear case from the axle KM538 CLEANING AND INSPECTING 1 Clean all parts with parts cleaning solvent and dry with compressed air 2 Inspect all seals for nicks tears or deterioration CAUTION Sup...

Страница 84: ...s Maximum runout is 3 mm 0 12 in NOTE Axle runout is equal to 1 2 the total dial indicator reading KM543 7 Check the final drive gear case assembly for smooth gear operation If gears are noisy or if there is any catching or binding the gear case assembly must be repaired DISASSEMBLING 1 Remove the cap screws securing the gear case cover to the gear case then remove the gear case cover and right ri...

Страница 85: ...shaft using the pinion puller then using a three jaw puller remove the pinion bearing Account for the pinion shim KM922 KM923 KM924A 4 Remove the oil seals from the case and cover then drive the bearings out of the case KM925 KM926 KM927 ...

Страница 86: ...inspect for nicks tears missing tension springs or excessive wear on lips ASSEMBLING 1 Drive the bearings into the gear case and gear case cover using an appropriate bearing driver Make sure the bearing is firmly seated KM926 KM928 2 Apply grease to the seal lips then using a seal driver drive the seals into the gear case and cover flat side out until flush with the seal bore KM927A KM925A 3 Drive...

Страница 87: ...f machinist s layout dye or paste to several ring gear teeth 7 Install the proper shims on the ring gear and install into the gear case then install the case cover and secure with the case cap screws Tighten in a criss cross pattern while rotating the pinion gear Checking Tooth Contact 1 Rotate the ring gear several turns in either direction then check gear contact through the oil filler hole 2 Ex...

Страница 88: ...g Backlash until both are within specifications 6 When tooth contact and backlash are within specifi cation remove the cap screws securing the cover to the gear case 7 Clean any oil from the mating surfaces then apply an even coat of silicone sealant to the mating sur faces and install the gear case covers 8 Install six 8 mm and two 10 mm cap screws and while rotating the pinion gear tighten in a ...

Страница 89: ...n while assembling 4 Insert the driveshaft assembly into the swing arm tube then engage the driveshaft splines with the pin ion shaft splines in the rear drive gear case KM530 5 Pack approximately 3 g 0 1 oz of grease into each swing arm pivot bearing cavity then apply grease to the lips of the dust seals KM531 6 Align the swing arm assembly in the frame and engage the universal joint onto the spl...

Страница 90: ...sc hub and wheel hubs then install the disc and rear hubs KM502 14 Install the hub nuts and tighten to 72 ft lb then install new cotter pins and bend as shown KM469 15 Install the rear brake calipers and tighten to 25 ft lb 16 Install the rear hub caps then install the rear wheels and tighten in a crisscross pattern to 40 ft lb 17 Remove the ATV from the support stand Front Brake Lever Master Cyli...

Страница 91: ...ts INSTALLING 1 Install the brakelight switch on the master cylinder then install the brake lever and brake lever lock 2 Install the master cylinder assembly on the handlebar engaging the alignment stud in the hole in the han dlebar then secure with the master cylinder clamp and two cap screws Make sure the UP arrow on the clamp is directed upward KM800C 3 Tighten the cap screws to 13 ft lb 4 Usin...

Страница 92: ...e 2 Secure the master cylinder to the frame with the two cap screws and tighten securely 3 Using two new crush washers connect the brake hose to the master cylinder with the union bolt then making sure the spring clamp is seated securely con nect the reservoir hose to the master cylinder Tighten the union bolt to 25 ft lb 4 Making sure the brake pedal is fully released and against the stop turn th...

Страница 93: ... Replace pads 2 Adjust free play 3 Repair replace hydraulic system 4 Bleed hydraulic system 5 Replace appropriate 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 Bleed hydraulic system 2 Add fluid to proper level bleed system 3 Replace with correct fluid 4 Replace master cylinder Prob...

Страница 94: ...Inspect the springs spring retainers shock rods shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Install each shock absorber to the frame and A arm with cap screws and nuts Tighten all nuts to 29 ft lb 2 Remove the ATV from the support stand Rear Shock Absorber REMOVING 1 Secure the ATV on a support stand to elevate the wheels and to release load on the suspension 2 Remove the lowe...

Страница 95: ...ning the adjuster collar A clockwise when viewed from above the shock to increase spring preload or counterclockwise to decrease spring preload XA090A NOTE To aid in adjusting preload safely lift the vehicle using a jack from under the frame Lift the vehicle high enough so the wheels are no longer touch ing the floor Front A Arms REMOVING 1 Secure the ATV on a support stand to elevate the front wh...

Страница 96: ...eal lips and spacers NOTE The pivots are equipped with roller bear ings The bearing rollers may fall out when the spac ers are removed 5 Check the bearings for excessive wear and replace them if worn 6 Using a suitable bearing remover remove the pivot bearings then clean all parts in parts cleaning sol vent SP382 NOTE All bearings bushings and seals that are removed must be replaced with new ones ...

Страница 97: ...sure should be as specified REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the wheels NOTE Keep left side and right side wheels sepa rated for installing them on their proper sides CLEANING AND INSPECTING 1 Clean the wheels and hubs with parts cleaning sol vent 2 Clean the tires with soap and water 3 Inspect each wheel for cracks dents or bends 4 Inspect each tire for ...

Страница 98: ...pulling is noted during braking only check and adjust the brakes as necessary and recheck operation see Periodic Maintenance Tune Up Hydraulic Brake Systems 5 Increase the air pressure in the 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 if tire d...

Страница 99: ...98 NOTES ...

Страница 100: ...99 NOTES ...

Страница 101: ...100 NOTES ...

Страница 102: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 971 Effective February 2017 2017 Arctic Cat Inc ...

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