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Front Brake Lever/

Master Cylinder

Assembly



NOTE: The master cylinder is a non-serviceable

component; it must be replaced as an assembly.

REMOVING

1. Place a shop towel under the brake hose union bolt

and disconnect the brake hose.

SP422

2. Remove the master cylinder assembly; then remove

the reservoir cap (3) and the diaphragm (4). Drain

the brake fluid.

SP423

3. Remove the brake lever (1) and brakelight switch

(2).

SP424

4. Pull the rubber boot (5) out; then remove the circlip

(6).

SP425A

5. Remove the piston (8), secondary cup (7), primary

cup (9), and spring (10).

SP427

INSPECTING



NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the pivot bolt securing the brake lever for

wear.

2. Inspect the brake lever for elongation of the pivot

hole.

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake hose for cracks and deterioration

and the condition of the fittings (threaded and com-

pression).

! CAUTION

Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the ATV.

Содержание DVX 400 2004

Страница 1: ...ATV Service Manual 2004 2004 2004 A A RC C C T T I DVX 400...

Страница 2: ...the words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals w...

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

Страница 4: ...SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS General Specifications 1 2 Break In Procedure 1 3 Gasoline Oil Lubricant 1 3 Genuine Parts 1 4 Preparation For Storage 1 5 Preparation After Storage 1...

Страница 5: ...032 in Ignition Coil Resistance primary secondary 0 1 1 0 ohm terminal to ground 13 000 20 000 ohms high tension plug cap removed to terminal Ignition Coil Peak primary CDI Voltage More than 130 volts...

Страница 6: ...maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area Tighten the gas tank cap securely after filling the tank Genuine Parts When replacement of p...

Страница 7: ...10 Store the ATV indoors in a level position Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free riding Arctic Cat recom...

Страница 8: ...2 11 Muffler Spark Arrester 2 12 Gas Vent Hoses 2 12 Adjusting Throttle Cable 2 12 Adjusting Engine RPM Idle 2 13 Engine Transmission Oil Filter 2 13 Adjusting Clutch Lever Cable 2 14 Tires 2 15 Stee...

Страница 9: ...Engine Transmission Oil Filter R R R Oil Strainer I I C Drive Chain I I A R Clutch I l A Tires Air Pressure I I R Steering Components I I R Coolant Hoses I l R 4 yrs Suspension Ball joint and tie rod...

Страница 10: ...tive battery cable then remove the positive cable and the battery vent tube Remove the battery from the ATV Care should be taken not to damage the vent tube 3 Trickle charge the battery at 0 9 amps fo...

Страница 11: ...Foam Filter Cleaner p n 0436 194 and Foam Filter Oil p n 0436 195 are available from Arctic Cat 6 Dry the filter 7 Put the filter in a plastic bag then pour in air filter oil and work the filter 8 Cl...

Страница 12: ...n loosen the clamp securing the air cleaner to the outlet tube 5 Remove the cap screws securing the air cleaner to the frame 6 Remove the air cleaner from the frame INSTALLING 0739 212 1 Place the air...

Страница 13: ...g for the two camshaft end plugs and the valve cover gasket SP121 NOTE The valve tappet clearance specification is different for intake and exhaust valves The clearance should only be checked when the...

Страница 14: ...ce NOTE Tappet shims are available in 25 sizes from 2 30 3 50 mm 0 09 0 14 in in 0 05 mm 0 002 in increments 4 Install the selected shim at the valve stem with the numbers facing the tappet Be sure to...

Страница 15: ...8 ATV2152...

Страница 16: ...9 ATV2153...

Страница 17: ...vice valves see Section 3 7 Pour 29 5 ml 1 fl oz of oil into the spark plug hole reattach the gauge and retest compression 8 If compression is now evident service the piston rings see Section 3 Spark...

Страница 18: ...cable free play follow this proce dure 1 Slide the rubber boot away then loosen the jam nut from the throttle cable adjuster AL611D 2 Slide the rubber boot away and turn the adjuster until the thrott...

Страница 19: ...ace drain pans under the oil tank drain plug 1 and the crankcase drain plug 2 then remove the plugs and drain the oil ATV2027 ATV2028 4 Remove the cap screws securing the filter cover 5 Remove the fil...

Страница 20: ...usting Clutch Lever Cable To adjust the cable use the following procedure 1 Pull rubber protective boot away from the cable adjusters 2 Loosen the lock nut then turn the adjuster to obtain 10 15 mm 0...

Страница 21: ...ap screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened to specifications For proper to...

Страница 22: ...on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when the most intense beam is centered on the verti cal mark 5 cm 2 in below the horizontal mark on the aiming surface ATV2051B...

Страница 23: ...compo nents and missing components If replacement or repair constitutes removal see Section 8 Electrical Connections The electrical connections should be checked periodi cally for proper function In...

Страница 24: ...the bleeder screw and tighten E Perform steps B C and D on the other FRONT bleeder screw repeating step C until no air bub bles are observed in the bleeder line Make sure that the brake lever is firm...

Страница 25: ...dure A Remove the caliper mounting cap screws 1 and the brake pad mounting pins 2 then remove the brake pads Account for the shims SP127 NOTE Do not compress the brake lever after the brake pads are...

Страница 26: ...pressed air blow dust and brake pad resi due from the caliper then install new brake pads and secure with the two mounting pins Tighten to speci fications and lock with the tabs on the washer SP117 8...

Страница 27: ...to 0 5 mph 3 Repeat procedure on each brake system five times until brake pads are burnished 4 Adjust the parking brake if necessary 5 Verify that the brakelight illuminates when the hand lever is com...

Страница 28: ...t 21 pins on the chain and measure the dis tance between the two points If this distance exceeds the service limit of 319 4 mm 12 57 in the chain must be replaced ATV2156 ADJUSTING To adjust the drive...

Страница 29: ...screws securing the drive sprocket cover then remove the cover SP134 7 Remove the drive sprocket cap screws and remove the sprocket 8 Install a new drive sprocket then apply red Loctite 271 to the dri...

Страница 30: ...SECTION 3 ENGINE TRANSMISSION Table of Contents Engine Transmission 3 2 Specifications 3 2 Table of Contents Removing Disassembling Assembling Installing 3 3 Table of Contents Servicing Components 3 1...

Страница 31: ...e ter 21 972 21 993 mm 0 8650 0 8658 in Camshaft Runout max 0 10 mm 0 004 in Cylinder Head Distortion max 0 05 mm 0 002 in Cylinder Head Cover max Distortion 0 05 mm 0 002 in CYLINDER PISTON AND RINGS...

Страница 32: ...2 Remove the negative cable from the battery then remove the positive cable Remove the battery hold down then remove the battery 3 Remove the radiator cap then drain the engine coolant 4 Remove the lo...

Страница 33: ...oke cable attached then secure the carburetor out of the way sufficiently to enable engine removal 13 Disconnect the two starter leads from the starter and secure them out of the way 14 Remove the eng...

Страница 34: ...g C Upper rear Four cap screws C through bolt A with nut and one mounting bracket D Lower rear One nut B and through bolt leav ing two collars D in the frame ATV2158 22 Work the engine forward to clea...

Страница 35: ...washers from the driven gear SP152 NOTE If the right side components are to be removed do not remove the rotor flywheel Pro ceed to step 7 4 Using a 27 mm offset box end wrench hold the rotor flywheel...

Страница 36: ...Gear E Oil Pump F Shift Shaft G Shift Cam Driven Gear H Balancer Driven Gear and Drive Gear I Neutral Switch 1 Remove the cap screws securing the clutch cover to the crankcase noting the position of t...

Страница 37: ...en remove the oil pipe 6 SP163 NOTE If the top side components have not been removed the tensioner and cam chain cannot be removed 9 Remove the oil pump idler gear 7 the oil pump driven gear 8 and the...

Страница 38: ...heel and using a 27 mm offset wrench remove the crank balancer driven gear nut then remove the washer driven gear and locater pin ATV2159A 14 Remove the primary drive gear nut washer and pri mary driv...

Страница 39: ...nly 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 not have to be removed fr...

Страница 40: ...3 then remove the camshaft journal cap screws and journal caps 4 SP182 NOTE Use caution not to drop the alignment pins or the camshaft drive chain into the crank case 4 Remove the four alignment pins...

Страница 41: ...ure cannot be done with the engine transmission in the frame Complete Removing procedures for Left Side Right Side and Top Side must precede this procedure NOTE For efficiency it is preferable to remo...

Страница 42: ...t pin 5 shift fork shaft 6 reverse lock shaft 7 shift forks 8 and the shift cam 9 NOTE Note the location of each shift fork for assembling purposes SP191 2 Remove the reverse idler gear and shaft then...

Страница 43: ...way replacement is necessary VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve faces and valve stem ends for pits burn marks or other signs of abnormal wear NOTE When...

Страница 44: ...cifications replace the cylinder head with a new one SP205 Measuring Valve Stem Runout 1 Support each valve stem end with the V Blocks p n 0644 022 then check the valve stem runout using a dial indica...

Страница 45: ...e then from top to bottom 4 Maximum wobble deflection must not exceed specifications Measuring Valve Guide Inside Diameter 1 Insert a snap gauge 1 2 way down into each valve guide bore then remove the...

Страница 46: ...ithin specifications NOTE Repeat procedure on the remaining exhaust valve CC139D 2 Insert an intake valve seat pilot shaft into one of the intake valve guides Slide the intake valve seat grind ing too...

Страница 47: ...rt areas 3 Inspect the piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or honing oil AN135 NOTE If scuffing or seizure marks are too deep to correct with the s...

Страница 48: ...be trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chamber being careful not to nick scrape or d...

Страница 49: ...ee locations from top to bottom and again from top to bottom at 90 from the first measurements for a total of six measurements The trueness out of round ness is the difference between the highest and...

Страница 50: ...nd camshafts 4 Match the width of the plastigauge with the chart found on the plastigauge packaging to determine camshaft to cylinder head journal clearance ATV2161 5 If clearance is excessive measure...

Страница 51: ...the starter torque limiter It is not serviceable To check the slip torque of the starter torque limiter use a holding fixture special socket and a torque wrench as shown If the slip torque is not wit...

Страница 52: ...r notches If grooves or notches are present replace the hub OIL PUMP Inspecting Servicing 1 Remove the outer rotor 1 inner rotor 2 and the pin 4 then inspect the outer and inner rotors for nicks scrat...

Страница 53: ...e the balancer driven gear noting the posi tion of the two pins A and alignment of the two punch marks SP214 Servicing Center Crankcase Components NOTE Whenever a part is worn excessively cracked dama...

Страница 54: ...bearing remover to pull the bearing from the crankcase SP218 SP219 6 Install the new bearing using the bearing installer then apply a small amount of red Loctite 271 to the bearing retainer screws an...

Страница 55: ...he crankshaft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the indicator contact at point 1 of the crank shaft ATV 1074 3 Zero the indicator and rotate the cran...

Страница 56: ...lip has been removed from a shaft it should be discarded and replaced with a new one NOTE When assembling the transmission shafts attention must be given to the position of the washers and circlips Th...

Страница 57: ...eshaft 6 In order install the reverse driven bushing reverse driven gear washer and circlip onto the driveshaft Make sure the oil hole in the reverse driven bushing aligns with the hole in the drivesh...

Страница 58: ...ft side on the drive shaft NOTE The driveshaft is now completely assem bled for installation COUNTERSHAFT Disassembling 1 Remove the 2nd drive gear and washer from the countershaft CC204D 2 Remove the...

Страница 59: ...ll the 4th drive washer and 4th drive gear onto the countershaft CC201D 5 Install the 2nd drive gear and washer onto the countershaft CC204D NOTE The countershaft is now completely assembled for insta...

Страница 60: ...heck to be sure that the gears all engage normally then shift the transmission into neutral 7 Verify that the two crankcase half alignment pins 1 are in place SP226 NOTE Prior to joining crankcase hal...

Страница 61: ...Gear NOTE It will be necessary to install the starter driven gear starter one way clutch and the rotor flywheel on the left side prior to installing right side components This is done to provide a mea...

Страница 62: ...e crank bal ancer driven gear nut to specifications ATV2169 SP236A C Shift Cam Driven Gear D Oil Pump E Cam Chain NOTE Steps 1 5 in the preceding sub section must precede this procedure 6 Install the...

Страница 63: ...gear aligning the pin 1 with the groove 2 and install the circlip SP240 SP241 10 Install the cam chain 1 onto the sprocket then install the cam chain tensioner and tighten the mounting bolt 2 to spec...

Страница 64: ...f 122 5 mm 4 82 in first Two dif ferent types of drive plates are used They are the one with the 122 5 mm 4 82 in inside diameter and seven with an inside diameter of 116 0 mm 4 5 in SP247 16 Referrin...

Страница 65: ...1 contacts 2 and a new O ring 3 then install the neutral switch and tighten the Allen head cap screws to specifications SP252A 2 Install the starter driven gear 1 dowel pins 2 and a new gasket 3 then...

Страница 66: ...om dropping into the crank case then install the piston piston pin and a new circlip with the punch mark 1 on the piston directed toward the exhaust side SP256 SP257 5 Apply engine oil to the sliding...

Страница 67: ...eding sub section must precede this procedure 8 Install the cylinder head on the cylinder 9 Lightly oil the threads of the 10 mm cap screws and the washers then install and tighten in two steps to spe...

Страница 68: ...ll the alignment pins 1 and cam chain guide then install the camshaft journal holder marked EX on the exhaust camshaft and the camshaft journal holder marked IN on the intake camshaft SP265 17 Making...

Страница 69: ...ing sequence A Lower rear One cap screw and nut with two spacers Tighten only until snug B Upper rear Loosely fasten the engine mount to frame cap screws then install the cap screw w nut and flat wash...

Страница 70: ...g connectors to the alternator lead wire coupler 3 and the neutral start lead coupler 4 then connect the starter cables SP277 9 Connect the reverse gear selector cable 6 then install the cable bracket...

Страница 71: ...le first and the negative cable last 17 Install the seat making sure it locks into position CAUTION If the engine had a major overhaul or if any major part was replaced proper engine break in procedur...

Страница 72: ...r 4 6 Throttle Cable Free Play 4 6 Engine RPM Idle 4 7 Gas Tank 4 7 Fuel Valve 4 8 Gas Vent Hoses 4 8 Oil Flow Chart 4 9 Oil Filter Oil Pump 4 10 Testing Oil Pump Pressure 4 10 Oil Tank 4 11 Liquid Co...

Страница 73: ...Valve 10 Ring 11 Spring 12 Washer 13 Jet Needle 14 O Ring 15 Washer 16 Pilot Screw 17 Spring 18 Main Jet 19 Ring 20 Jet Holder 21 Jet 22 Pin 23 Needle Valve Assy 24 O Ring 25 Needle Jet 26 Plunger As...

Страница 74: ...er Account for the O ring 7 SP279 7 Disconnect the throttle cable from the actuator arm then loosen the outer jam nut 6 securing the throttle cable to the carburetor body and route the cable out of th...

Страница 75: ...disassembling procedures SP287A 6 Secure the needle jet holder with a wrench then remove the main jet 7 Remove the needle jet holder then remove the pilot jet and the starter jet 8 Remove and install...

Страница 76: ...he O ring is properly positioned then secure with the Phillips head screws 6 Position the spring and primer diaphragm assembly lip toward the carburetor onto the carburetor then secure the assembly wi...

Страница 77: ...rtion 10 Inspect all jets for obstructions or damage NOTE If the pilot jet is obstructed the mixture will be extremely lean at idle and part throttle oper ation 11 Inspect the carburetor mounting flan...

Страница 78: ...spect all hoses for cracks or leaks 3 Inspect fuel valve tank cap and tank for leaks holes and damaged threads INSTALLING 1 Place the gas tank into position on the frame then install the cap screws Ti...

Страница 79: ...2 Remove the two nuts securing the fuel valve then remove the valve Account for the gasket 3 Inspect the gasket and fuel valve tank mating sur faces for damage or deterioration 4 Inspect for and remo...

Страница 80: ...9 Oil Flow Chart ATV2180...

Страница 81: ...ctic Cat Engine Tachometer p n 0644 275 to the engine 2 Remove the oil galley plug then connect the Oil Pressure Gauge p n 0444 039 to the galley using an appropriate adapter SP004A NOTE Some oil seep...

Страница 82: ...rs are service able then install the tank onto the frame and tighten the cap screws securely SP291 2 Install new O rings to the upper and lower tank fit tings then secure the fittings to the tank and...

Страница 83: ...eck AN604D Radiator 0739 218 REMOVING 1 Drain the coolant from the engine then remove the seat and body see Section 8 2 Disconnect the negative battery cable then discon nect the positive cable 3 Remo...

Страница 84: ...ant from the cooling system 2 Remove the hose clamp securing the upper coolant hose to the thermostat housing then remove the ther mostat housing and the thermostat SP294 INSPECTING NOTE Whenever a pa...

Страница 85: ...SP297 3 Remove the cap screws securing the clutch cover then depress the brake pedal and remove the clutch cover SP298 4 Remove the water pump case then remove the cir clip 1 water pump driven gear 2...

Страница 86: ...onents in cleaning solvent 2 Inspect the impeller shaft for corrosion or damage ASSEMBLING 1 Place the new oil seal into the housing then using a seal driver gently tap the seal down until it is fully...

Страница 87: ...s tem with the recommended amount of coolant AN604D NOTE While the cooling system is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engi...

Страница 88: ...olant should be between upper and lower level marks Cooling Fan Thermo Switch REMOVING 1 Drain the coolant in the radiator to a point below the lower temperature switch 2 Disconnect the cooling fan th...

Страница 89: ...18 NOTES...

Страница 90: ...ature and Cooling Fan Switches 5 4 Fan Motor 5 4 Fuse Holder 5 4 Fuse 5 5 Ignition Coil 5 5 Indicator Lights 5 6 Ignition Switch 5 7 Handlebar Control Switches 5 7 Neutral Switch 5 8 Clutch Lever Posi...

Страница 91: ...always verify first that the fuse is good that the bulbs are good that the con nections are clean and tight that the battery is fully charged and that all appropriate switches are activated NOTE For...

Страница 92: ...AR621D 3 When the pedal is depressed the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resistance troubleshoot or replace the switch component the connector or the switch...

Страница 93: ...volt D C power supply then connect the black red wire from the fan connector to ground The fan should operate Fuse Holder The fuse and a spare are located on the starter relay under the seat SP032A 1...

Страница 94: ...ton 5 The meter reading must be within specification NOTE If the voltage is not as specified inspect the main wiring harness connectors source charge coil magneto rotor and magnets magneto rotor key o...

Страница 95: ...D C Voltage position 2 Connect the red tester lead to the orange wire then connect the black tester lead to ground 3 The meter must show battery voltage NOTE This is the only voltage test for all ind...

Страница 96: ...the OHMS position 2 Connect the red tester lead to the orange white wire then connect the black tester lead to the black wire 3 With the starter button depressed the meter must show less than 1 ohm 4...

Страница 97: ...battery post then connect the black tester lead to the nega tive battery post 3 With the engine running at a constant 5000 RPM with the headlights on the meter must be within specification NOTE If vo...

Страница 98: ...nect the black tester lead to the white wire 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Starter Motor REMOVING DISASSEMBLING 0739 228 1 Disconn...

Страница 99: ...ground hack saw blade Do not undercut any deeper than the orig inal groove which can be seen by looking at the end of the commutator 9 Using a caliper measure the undercut Maximum undercut groove mus...

Страница 100: ...switch must be in the ON position the emergency stop switch in the RUN position the reverse lever on manual transmis sion models in the FORWARD position and the shift lever on automatic transmission m...

Страница 101: ...s sub section NOTE If the charge coil test is within specifica tions replace the regulator rectifier Headlights The headlight are halogen bulbs with two wire plug connectors The headlight housing cont...

Страница 102: ...D C Voltage position 2 Connect the red tester lead to the black white wire then connect the black tester lead to the white black wire 3 With either brake applied the meter must show bat tery voltage...

Страница 103: ...14 WIRING DIAGRAM Harness p n 3509 007 Insert Fold Out 0739 430...

Страница 104: ...1 SECTION 6 DRIVE SYSTEM Table Of Contents Drive System 6 2 Rear Drive Assembly Schematics 6 2 Rear Drive Axle 6 3...

Страница 105: ...nd lock the parking brake then remove the wheels 3 Loosen but do not remove the four cap screws on the swing arm then turn the adjuster nut counter clockwise to slacken the chain KEY 1 Hub 2 Wheel 3 N...

Страница 106: ...e brake disc from the flange SP316 NOTE It is not necessary to remove the right side axle nut SP317 NOTE Do not attempt to remove the brake disc flange The axle and brake flange are an assembly 7 Remo...

Страница 107: ...9 2 Clean the axle housing and inspect for cracks elon gated holes and wear in bearing bores INSTALLING BEARINGS 1 Pack the new bearings with a good quality wheel bearing grease then install the right...

Страница 108: ...ing the following formula due to the offset of the special tool used to tighten the axle nuts ATV2188 SP323 T Torque wrench reading to be calculated Ts Specified torque value 130 ft lb Ls Tool offset...

Страница 109: ...6 NOTES...

Страница 110: ...1 SECTION 7 SUSPENSION Table Of Contents Front and Rear Suspension Assembly Schematics 7 2 Shock Absorbers 7 2 Swing Arm 7 5 Front A Arms 7 10 Wheels and Tires 7 15...

Страница 111: ...ront Arm Assy 2 Bearing 3 Bearing 4 Grease Fitting 5 Spacer 6 Dust Seal 7 Cap Screw 8 Nut 9 Spacer 10 Spacer 11 Cap Screw 12 Dust Seal 13 Spacer 14 Guard 15 Screw 16 Rear Arm 17 Spacer 18 Cap Screw 19...

Страница 112: ...the retainer 2 Install each shock absorber to the frame and A arm with cap screws and nuts Tighten all nuts to specifi cations 3 Remove the ATV from the support stand REMOVING REAR SHOCK 1 Secure the...

Страница 113: ...orber in position then install the upper and lower cap screws and nuts 2 Tighten the upper nut 1 and the lower nut 2 to specifications SP332A 3 Install the rear arm lower cap screw and nut then tighte...

Страница 114: ...2 Turn the adjuster 16 clicks counterclockwise for the standard setting Compression 1 Turn the upper damping force adjuster screw fully clockwise SP337 2 Turn the adjuster two full turns counterclockw...

Страница 115: ...orber then remove the rear wheels 5 Remove the axle housing see Section 6 6 Remove the brake hose guide 1 then remove the parking brake cable guide 2 SP341 SP342 7 Remove the swing arm pivot nut then...

Страница 116: ...or wear or damage If any defect is found they must be replaced 2 To inspect swing arm bearings and bushings insert the spacer 1 into the bearing 2 and bushing 3 then check for excessive play by moving...

Страница 117: ...must be replaced SP351 SP352 6 Remove the dust seals then using a suitable bearing puller and slide hammer remove the defective bear ing NOTE Removed bearings must be replaced with new ones SP353 SP3...

Страница 118: ...marks directed towards the outside then lubricate the bearing bushings and seal lips with multipurpose grease SP358A 3 Apply multipurpose grease to the lip of the dust cov ers then install the dust c...

Страница 119: ...A 7 Install the rear arm bolts and nuts then tighten the nuts 3 and 4 to specifications SP365 8 Install the rear arm guard and the swing arm guard Front A Arms REMOVING 1 Secure the ATV on a support s...

Страница 120: ...end to the knuckle then remove the tie rod end from the knuckle SP369 7 Remove the brake hose clamp 1 then remove the front bumper assembly 3 SP370 SP371 8 Remove the shock absorber lower mounting cap...

Страница 121: ...sed air If any damage or excessive wear is detected the knuckle must be replaced SP375 2 Inspect the ball joint for boot damage or wear Remove the circlip and replace the ball joint if dam age is foun...

Страница 122: ...then clean all parts in parts cleaning sol vent SP382 NOTE All bearings spacers and seals that are removed must be replaced with new ones INSTALLING 1 Using a bearing installer install the ball joint...

Страница 123: ...bores then install the arms to the steering knuckle and tighten the ball joint nuts to specifica tions Install new cotter pins NOTE During assembly new cotter pins should be installed SP388A SP390 6 I...

Страница 124: ...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 SP054 CLEANING AND INSPECTING NOTE Whenever a p...

Страница 125: ...and have it repaired professionally NOTE Be sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe in and toe out and adjust as necessary see Section 8 4 T...

Страница 126: ...1 SECTION 8 STEERING FRAME Table Of Contents Steering Post Tie Rods 8 2 Measuring Adjusting Toe In Toe Out 8 7 Body 8 8...

Страница 127: ...on switch 5 with the parking brake engagement pin A depressed Remove the handlebar switch assem bly 6 SP396 4 Remove the steering head cover 7 then remove the harness clamps 8 KEY 1 Steering Post 2 Du...

Страница 128: ...the engine oil from the oil tank then drain the coolant from the radiator 7 Remove the radiator assembly 1 See Section 4 SP399 8 Remove the two fasteners then remove the oil hose protector SP400 9 Di...

Страница 129: ...ws SP406 SP407 SP408 12 Remove the hose and cable guide then remove the steering post holder 13 Remove the steering post 9 then remove the dust seals 10 and the steering post holder half 11 SP409 14 R...

Страница 130: ...y multipurpose grease to the steering post and dust seal then install the dust seal 1 to the steering post SP411 2 Install a new O ring 2 and the dust seal into the steering housing then install the w...

Страница 131: ...e the handlebar 1 handlebar holder 2 and steering head cover bracket 3 with the stepped end of the lower holder A directed rearward then finger tighten the cap screws ATV2202 9 Adjust the handlebar in...

Страница 132: ...ad using a suitable means of mea suring centering then adjust tire pressure to specifications 2 Place suitable ballast of 75 kg 165 lb of weight on the seat then loosen the lock nuts 1 and 2 on each t...

Страница 133: ...support mounting nuts SP098 3 Remove the front fender support brackets from the frame leaving them attached to the body SP099 4 Remove the two nuts from the plastic studs on the upper forward support...

Страница 134: ...ody over the handlebar and rotate into nor mal mounting position 2 Seat the two upper forward support studs and the rear fender support studs into the brackets then install the nuts and tighten secure...

Страница 135: ...10 SP106 SP107 7 Install the starter relay then install the seat making sure it is locked securely front and rear...

Страница 136: ...TION 9 CONTROLS INDICATORS Table Of Contents Front Brake Lever Master Cylinder Assembly 9 2 Rear Brake Pedal Master Cylinder Assembly 9 3 Throttle Control 9 5 Gearshift Pedal 9 6 Reverse Selector Lock...

Страница 137: ...Pull the rubber boot 5 out then remove the circlip 6 SP425A 5 Remove the piston 8 secondary cup 7 primary cup 9 and spring 10 SP427 INSPECTING NOTE Whenever a part is worn excessively cracked or dama...

Страница 138: ...ning with the upper clamp bolt tighten the mounting bolts to specifications 5 Connect the brake hose union bolt 1 to the master cylinder then with the stopper against the master cylinder tighten the b...

Страница 139: ...sh all master cylinder components in new brake fluid before assembling Do not dry components 1 Apply brake fluid to the master cylinder bore then install the piston with cups 2 Install the push rod an...

Страница 140: ...the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm to the throttle control lever AF677D 4 Remove the actuator arm and account for a bushing...

Страница 141: ...the pedal for first gear and reverse gear and lifting up on the pedal for second through fifth gear The ratchet mech anism makes it impossible to upshift or downshift more than one gear at a time Reve...

Страница 142: ...1 SECTION 10 AIDS FOR MAINTENANCE Table Of Contents Torque Specifications 10 2 Torque Conversions 10 3 Tightening Torque General Bolts 10 3...

Страница 143: ...ar Brake Caliper 2 3 16 5 Front Brake Pipe Nut Brake Line Junction Block 1 6 11 5 Brake Caliper Rear Swing Arm Housing 2 6 19 Brake Pad Mounting Pins Caliper 1 8 13 Rear Master Cylinder Push Rod Lock...

Страница 144: ...70 9 7 90 12 5 11 1 5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14 1 9 34 4 7 54 7 5 74 10 2 94 13 0 15 2 1 35 4 8 55 7 6 75 10 4 95 13 1 1...

Страница 145: ...1 SECTION 11 TROUBLESHOOTING Table Of Contents Engine 11 2 Fuel System 11 7 Electrical 11 8 Steering Suspension 11 10 Brakes 11 11...

Страница 146: ...valve Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Carburetor jets obstructed 5 Valve clearance out of adjustment 1 Clean plug 2 Replac...

Страница 147: ...ism Problem Transmission will not shift Condition Remedy 1 Gearshift cam broken 2 Gearshift forks distorted 3 Gearshift shaft worn 4 Clutch cable out of adjustment 5 Reverse selector cable adjusted im...

Страница 148: ...p incorrect 9 Carburetor jets obstructed 10 Float level out of adjustment 11 Air cleaner element obstructed 12 Oil in the engine overfilled contaminated 13 Intake manifold leaking air 14 Cam chain wor...

Страница 149: ...et 2 Clean outlet 3 Adjust screw 4 Adjust valve 5 Adjust float height Problem Medium or high speed impaired Condition Remedy 1 Main jet obstructed 2 Needle jet obstructed 3 Throttle vacuum piston not...

Страница 150: ...emedy 1 Lead wires shorted open loose at terminals 2 Stator coils magneto grounded open 3 Regulator rectifier defective 4 Cell plates battery defective 1 Repair tighten lead wires 2 Replace stator coi...

Страница 151: ...rame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pres...

Страница 152: ...crews Problem Braking poor Condition Remedy 1 Pad worn 2 Pedal free play excessive 3 Brake fluid leaking 4 Hydraulic system leaking air 5 Master cylinder brake cylinder seal worn 1 Replace pads 2 Adju...

Страница 153: ......

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