Arctic Cat 2010 366, Service Manual

Page 1: ...ol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death A CAUTION identifies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE identifies supplementary information worthy...

Page 2: ...word Section 1 General Information Specifications 2 Periodic Maintenance 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 1 2 3 4 5 6 7 8 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 3: ...ons 1 2 Torque Conversions ft lb N m 1 3 Tightening Torque General Bolts 1 3 Break In Procedure 1 3 Gasoline Oil Lubricant 1 3 Genuine Parts 1 4 Preparation For Storage 1 4 Preparation After Storage 1 5 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 4: ...m Frame 35 47 Knuckle Ball Joint 35 47 Shock Absorber Frame 35 47 Shock Absorber Upper A Arm 35 47 Knuckle A Arm 35 47 SUSPENSION COMPONENTS Rear Shock Absorber Upper Frame 35 47 Shock Absorber Lower Lower A Arm 35 47 A Arm Frame 35 47 Knuckle A Arm 35 47 ENGINE TRANSMISSION Clutch Shoe Crankshaft 147 199 Clutch Cover Housing Assembly Crankcase 8 11 Left Side Cover Crankcase 8 11 Crankcase Half 6 ...

Page 5: ...e to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not neces sary to add a gasoline antifreeze since ethanol will pre vent the accumulation of moisture in the fuel system ft lb N m ft lb N m ft ...

Page 6: ...iption Preparation For Storage Arctic Cat recommends the following procedure to prepare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV to dry thoroughly DO NOT get water into any part of the engine or air intake CAUTION Any oil used in p...

Page 7: ...ic Cat recommends the following procedure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the muf fler 3 Check all control cables for signs of wear or fray ing Replace if necessary 4 Change the engine transmission oil and filter 5 Charge the battery then install Connect the bat tery cables 6 Check the entire brake systems fluid level pads etc all controls lig...

Page 8: ...tle Cable 2 8 Adjusting Engine RPM Idle 2 9 Engine Transmission Oil Filter Strainer 2 9 Front Differential Rear Drive Lubricant 2 10 Tires 2 11 Steering Components 2 11 Driveshaft Coupling 2 11 Suspension Shock Absorbers Bushings 2 11 Nuts Bolts Cap Screws 2 12 Ignition Timing 2 12 Lights 2 12 Shift Lever 2 14 Frame Welds Racks 2 15 Electrical Connections 2 15 Hydraulic Brake Systems 2 15 Burnishi...

Page 9: ...er C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R Carburetor Float Chamber D Engine Idle RPM I I A Engine Transmission Oil Level I A Engine Transmission Oil Filter R R R R Oil Strainer I I C Front Differential Rear Drive Lubricant I I R 4 Yrs Tires Air Pressure I I R Steering Components I I I R V Belt I l R Suspension Ball joint boots drive axle boots front and rear tie rods differentia...

Page 10: ...ent then thoroughly wash the battery and battery com partment with soap and water NOTE If battery posts cable ends or the battery case has a build up of white green powder residue apply water and baking soda to neutralize acid then flush off with warm soapy water 4 Using a wire brush clean the battery posts and cable ends removing all corrosive buildup Replace damaged cables or cable ends 5 Add cl...

Page 11: ...s a 30 amp fuse on the starter relay under the seat next to the bat tery If there is any type of electrical system failure always check the fuses first NOTE To remove a fuse compress the locking tabs on either side of the fuse case and lift out 0411 837 Air Filter Use the following procedure to remove the filter and inspect and or clean it CLEANING AND INSPECTING FILTER 1 Rotate the three locking ...

Page 12: ...ebris from inside the air cleaner Be sure no dirt enters the carburetor 7 Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter element straight in the hous ing KC147 8 Install the air filter housing cover and secure with the locking tabs KC123 CAUTION A torn air filter element can cause damage to the ATV engine Dirt and dust ...

Page 13: ...ment CC007DC 4 Install the timing inspection plug 5 Place the two tappet covers with O rings into posi tion then tighten the covers securely 6 Install the spark plug then install the timing inspection plug Valve Tappet Clearance Valve Adjuster Procedure To check and adjust valve tappet clearance use the following procedure NOTE The seat left side and right side engine covers and gas tank must be r...

Page 14: ...e plug on the cylinder head well away from the spark plug hole 4 Attach the Compression Tester Kit NOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the throttle lever in the full open position crank the engine over with the electric starter until the gauge shows a peak reading of 95 115 psi five to 10 compression strokes 6 If compression is abnormall...

Page 15: ... damage the screen NOTE If the screen or gasket is damaged in any way it must be replaced 3 Install the spark arrester assembly with gasket then secure with the cap screws Tighten to 48 in lb KC145 Adjusting Throttle Cable To adjust the throttle 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 Turn the adjuster un...

Page 16: ...ll the plug and tighten securely 6 Using the adjustable Oil Filter Wrench and a suit able 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 correctly then install the new oil filter Tighten securely 8 Install the engine drain plug and tighten to 20 ft lb Pour the specified amount of ...

Page 17: ...ap screws Tighten securely 5 Place the strainer cap into position on the strainer making sure the O ring is properly installed then secure with the cap screws Tighten securely CC091D 6 Install the belly panel Front Differential Rear Drive Lubricant When changing the lubricant use approved SAE 80W 90 hypoid gear lube To check lubricant remove the rear drive filler plug the lubricant level should be...

Page 18: ...grips not worn broken or loose B Handlebar not bent cracked and has equal and complete full left and full right capability C Steering post bearing assembly bearing housing not broken worn or binding D Ball joints not worn cracked or damaged E Tie rods not bent or cracked F Knuckles not worn cracked or damaged G Cotter pins not damaged or missing Driveshaft Coupling The following drive system compo...

Page 19: ...oil bracket may be bent or damaged or the CDI unit may be faulty Lights Rotate the ignition switch to the lights position the headlights and taillights should illuminate Test the brakelights by compressing the brake lever The brake lights should illuminate HEADLIGHTS NOTE The bulb portion of a headlight is fragile HANDLE WITH CARE When replacing a headlight bulb do not touch the glass portion of t...

Page 20: ...the tail lights brakelights 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 KC158A 2 Install a new bulb and press in rotating clockwise to secure then place the socket into the light hous ing and turn clockwise to secure KC158B CHECKING ADJUSTING H...

Page 21: ...hift the transmission into each of the gear positions and note that the gear position indicated on the LCD cor responds to the gear position selected by the lever If the indicator does not correspond to the selected gear it will be necessary to test drive the ATV to deter mine if the gear shift position switch is faulty or the shift lever needs adjustment If the ATV functions in the gear selected ...

Page 22: ...eck the fluid level in the reservoir On the hand brake if the level in the reservoir is adequate the sight glass will appear dark If the level is low the sight glass will appear clear On the auxiliary brake the level must be between the MIN and MAX lines on the reservoir 738 420A AL681 2 Compress the brake lever pedal several times to check for a firm brake If the brake is not firm the system must...

Page 23: ...xcessive wear Check the thickness of each of the brake pads 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 pads must be replaced PR376B NOTE The brake pads should be replaced as a set 4 To replace the brake pads use the following proce dure A Remove the wheel B Remove the cap screws securing the ...

Page 24: ...ew securing the auxiliary brake pedal to the frame Account for a flat washer KC149A 2 Slide the auxiliary brake pedal part way off the pivot stud but do not remove then remove the cap screws from the V belt housing and remove the cover Account for two alignment pins and a gas ket KC142A 3 Remove the nut securing the movable drive face to the clutch shaft then remove the movable drive face assembly...

Page 25: ...rrows point in the direction of rotation then pinch the belt together in front of the driven pulley and place it over the clutch shaft KC135 KC131 2 Install the bushing over the clutch shaft then install the movable drive face assembly on the clutch shaft KC128 KC138 3 With two drops of red Loctite 271 on the threads and with the splines of the clutch shaft protruding through the movable drive fac...

Page 26: ... gasket in place install the V belt cover Using the pattern shown secure with the cap screws tightened to 8 ft lb KC142A KC153A 6 Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder then secure with the flat washer and cap screw and tighten to 20 ft lb KC149A Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 96...

Page 27: ...SMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Troubleshooting 3 3 366 Table of Contents 3 6 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 28: ...r 5 000 5 015 mm Valve Stem Outside Diameter intake exhaust 4 975 4 990 mm 4 955 4 970 mm Valve Stem Runout max 0 05 mm Valve Head Thickness intake exhaust 2 03 mm 2 28 mm Valve Face Seat Width min intake exhaust 2 25 mm 2 55 mm Valve Seat Angle intake exhaust 45 Valve Face Radial Runout max 0 03 mm Valve Spring Free Length min 42 8 mm Valve Spring Tension 32 5 mm outer 18 6 21 4 kg 41 47 lb CAMSH...

Page 29: ...Clean replace hose 4 Clean replace inlet screen valve screen 5 Replace fuel pump 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 Replace magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 V...

Page 30: ...obstructed 11 Pilot screw setting improper 12 Fuel injector obstructed 1 Adjust clearance 2 Replace service seats valves 3 Replace cylinder head 4 Replace arms shafts 5 Replace magneto 6 Replace CDI unit 7 Adjust gap replace plug 8 Replace ignition coil 9 Adjust float height 10 Clean jets 11 Adjust pilot screw 12 Replace fuel injector Problem Engine runs poorly at high speed Condition Remedy 1 Hig...

Page 31: ...shafts 8 Adjust gap replace plug 9 Clean jets 10 Adjust float height 11 Clean element 12 Drain excess oil change oil 13 Tighten replace manifold 14 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 2 Oil low 3 Octane low gasoline poor 4 Oil pump defective 5 Oil circuit obstructed 6 Gasoline level in float chamber too low 7 Intake manifold leaking a...

Page 32: ... left and right footwells and front body panel see Section 8 then discon nect the negative battery cable from the battery 2 Remove the heat shield then remove the gas tank see Section 4 3 Remove the oil fittings from the engine and account for two O rings then disconnect the oil temperature connector and cooling fan connector KC251 KC250 KC249 4 Disconnect the speedometer sensor then remove the E ...

Page 33: ...der head then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe Account for a grafoil seal and seal ring KC170 KC238 7 Disconnect the gear shift position switch starter cable and engine ground cable then disconnect the trigger coil and stator coil connectors KC228A Next Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9...

Page 34: ...from the frame for this procedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appropriate wrench rotate the crankshaft to top dead center of the compression stroke NOTE Arctic Cat recommends the use of new gaskets lock nuts and seals and lubricating all internal components wh...

Page 35: ... MD1354A 3 Loosen the cap screw on the end of the cam chain tensioner then remove the two cap screws secur ing the cam chain tensioner assembly Remove the tensioner assembly and gasket MD1245 4 Remove the cam chain tensioner pivot cap screw and washer MD1251 5 Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft MD1136 MD1137 Next Back Section Table of Contents ...

Page 36: ...he two lower nuts securing the cylinder head to the cylinder one in front and one in rear MD1192 9 Remove the four cylinder head cap screws and washers Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left spark plug side CD211 10 Remove the cylinder head from the cylinder remove the gasket and account for two al...

Page 37: ...Support the connecting rod with rubber bands to avoid damaging the rod or install a con necting rod holder NOTE If the existing rings will not be replaced with new rings note the location of each ring for proper installation When replacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence AT THIS POINT To service cylinder see Servicing T...

Page 38: ...before assembly by continuing to move the 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 valve set for use during installation Return each valve set to its original location during installation 1 Using a valve spring compressor compress the valve spr...

Page 39: ...e ATV 1004 2 Acceptable width must be at or above specifica tions Measuring Valve Face Radial Runout 1 Mount a dial indicator on the surface plate then place the valve stem on a set of V blocks 2 Position the dial indicator contact point on the out side edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications Measuri...

Page 40: ...eter 1 Using a micrometer measure the outside diameter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifications Installing Valves 1 Apply grease to the inside surface of the valve seals then place a lower spring seat and valve guide seal over each valve guide CC144D 2 Insert each valve into its original valve location 3 Install the valve springs with the painted en...

Page 41: ... to a sharp edge 2 Using the sharpened ring as a tool clean carbon from the ring grooves Be sure to position the ring with its tapered side up Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cylinder 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must be within...

Page 42: ...LY NOTE If the cylinder cylinder head assembly cannot 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 damage the combustion chamber or the sealing surface 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a heli coil ...

Page 43: ...d it must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90 from the first measurements for a total of six measurements The trueness out of roundness is the difference between the highest and lowest reading Maximum trueness out of roundness must not excee...

Page 44: ...cessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Loosen the jam nuts and adjuster screws CC005D 2 Place a strip of plasti gauge in each of the cam shaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap screws Tighten securely NOTE Do not rotate the...

Page 45: ...ng Top Side Components A Piston B Cylinder 1 Lubricate the piston pin connecting rod and piston pin bore with motor oil then install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip is directed upwards or downwards NOTE The piston should be installed so the arrow points towards the exhaust MD1213 2 Place the two alignment pins into positi...

Page 46: ...e 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder MD1349 6 Place a new 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 routed through the chain cavity MD1347 MD1163 CAUTION The cylinder should slide on easily Do not force the cylinder or dam...

Page 47: ...ming mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface NOTE When the camshaft assembly is seated make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket 13 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed sid...

Page 48: ...then bend the tab to secure the cap screw MD1137 19 Rotate the crankshaft until the first cap screw from step 17 securing the sprocket to the cam shaft can be addressed then tighten to 11 ft lb Bend the tab to secure the cap screw 20 Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards 21 Remove the cap screw from the end of the chain tensioner ...

Page 49: ...261 28 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 27 to 8 ft lb 29 Adjust valve tappet clearance see Section 2 30 Place the two tappet covers with O rings into posi tion then install and tighten the cap screws securely MD1264 31 Install the spark plug and tighten securely then install the timing inspection plug Left Side Components NOTE Fo...

Page 50: ...r for any shaft washers that may have come off with the cover Make sure they are returned to their respec tive shafts and that the starter idler gear spacer is on the shaft or in the cover B Rotor Flywheel C Starter Motor NOTE Steps 1 3 in the preceding sub section must precede this procedure 4 Remove the rotor flywheel nut MD1194 5 Install the crankshaft protector MD1365 6 Using Magneto Rotor Rem...

Page 51: ...cam 10 Remove the cam stopper assembly 11 Remove two starter motor cap screws KC217 12 Remove starter motor by tapping lightly with a mallet NOTE The starter motor is a non serviceable component and must be replaced as an assembly 13 Using an impact screwdriver remove the three Phillips head screws holding the crankshaft bear ing retainer Remove the crankshaft bearing retainer MD1122 Next Back Sec...

Page 52: ...7 Place the key into its notch then slide the rotor flywheel with the ring gear in place over the crankshaft Tighten the nut to 107 ft lb C Cover NOTE Steps 1 7 in the preceding sub section must precede this procedure 8 Install two alignment pins and place the left side cover gasket into position Install the left side cover Noting the different lengthed 6 mm cap screws the position of the shifter ...

Page 53: ...r then slide the brake pedal out ward and remove the V belt cover Account for two alignment pins and a gasket KC142A 3 Mark the movable drive face and the fixed drive face for installing purposes then remove the nut holding the movable drive face onto the crank shaft MD1033 4 Remove the movable drive face and spacer Account for the movable drive face rollers and outer drive face cover MD1035 AT TH...

Page 54: ...ht side crankcase half Note the posi tions of the different lengthed cap screws for installing purposes 10 Using a rubber mallet loosen the clutch cover then pull it away from the right side crankcase half Account for two alignment pins and gasket MD1115 D Gear Shift Position Switch E Centrifugal Clutch Assembly F Oil Pump Drive Gear G Oil Pump Driven Gear NOTE Steps 1 10 in the preceding sub sect...

Page 55: ... installing purposes MD1286 14 Remove the left hand threaded nut holding the centrifugal clutch assembly MD1014 MD1016 15 Remove the cam chain MD1335 16 Remove the oil pump drive gear cap screw MD1018 17 Remove oil pump drive gear Account for the pin CAUTION Care must be taken when removing the nut it has left hand threads Next Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT...

Page 56: ...ding the oil pump and remove the oil pump Account for two alignment pins MD1060 21 Remove the four cap screws securing the oil strainer cap then remove the Phillips head screws securing the oil strainer Account for the O ring MD1207 AT THIS POINT To service clutch components see Servicing Right Side Components sub section AT THIS POINT To service center crankcase components only pro ceed to Separa...

Page 57: ...SIDE directed away from the clutch shoe KC330 2 Place the clutch housing onto the clutch shoe one way clutch NOTE It will be necessary to rotate the clutch housing counterclockwise to properly seat the one way clutch KC331A 3 Check that the clutch shoe can only be rotated counterclockwise in respect to the clutch housing If the clutch shoe locks up or turns either direction the one way clutch must...

Page 58: ... on the crankcase and secure with the Phil lips head screws coated with blue Loctite 243 Tighten to 8 ft lb MD1060 4 Place the thrust washer and drive pin into position on the oil pump shaft install the oil pump driven gear making sure the recessed side of the gear is directed inward and secure with a new snap ring NOTE Always use a new snap ring when install ing the oil pump driven gear MD1020 MD...

Page 59: ...r and switch making sure to align the drive pin with the slot in the shift shaft KC325A KC326B B Clutch Cover C Fixed Drive Face D Movable Drive Face NOTE Steps 1 9 in the preceding sub section must precede this procedure 10 Install two alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 11 Tighten the clutch cover cap screws to 8 ft lb CAUTION Care must ...

Page 60: ...g until the faces open sufficiently to allow the V belt to drop into the pulley approxi mately 3 4 in KC137 NOTE The arrows on the V belt should point in direction of engine rotation 16 Making sure the movable drive face rollers are in position pinch the V belt together near its center and slide the spacer and movable drive face onto the shaft KC127 17 Coat the threads of the nut with red Loctite ...

Page 61: ...ve and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the left side and right side cap screws securing the crankcase halves noting the position of the different sized cap screws for joining purposes MD1006 MD1012 2 Using Crankcase Separator Crankshaft Remo...

Page 62: ...washer MD1325 3 Remove the driveshaft MD1326 4 Remove the shift fork shaft and the outer shift fork MD1327 5 Remove snap ring and gear from the output side of the gear cluster Remove the gear cluster and the inner shift fork together Account for snap ring gear and washer MD1328 6 Noting the position of the slot on the end remove the shift cam assembly Account for inner and outer washers Next Back ...

Page 63: ... the secondary driven output shaft assembly onto the crankcase 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 05 0 33 mm 0 002 0 013 in Correcting Backlash NOTE If backlash measurement is within the accep...

Page 64: ... chart NOTE To correct tooth contact steps 1 and 2 with NOTE of Correcting Backlash must be fol lowed and the above Tooth Contact Shim Correc tion chart must be consulted 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 mea sure it with micrometer CC290D 2 Maximum diameter must not ex...

Page 65: ... the other end of the crankshaft by positioning the indicator con tact at point 2 and following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the outside edge of one web to the outside edge of the other web ATV 1017 2 Acceptable width range must be within specifications COUNTERSHAFT Disassembling 1 Remove the reverse driven gear dog then remove the circlip ...

Page 66: ...ut shaft was removed make sure that the proper shim is installed 1 Install the output shaft into the crankcase making sure the two gears shim washer and nut are in the correct order MD1199 MD1079 2 Apply red Loctite 271 to the threads of the output shaft Install and tighten the nut 59 ft lb Using a punch peen the nut MD1333 3 Apply a liberal amount of oil to the crankshaft bearing Using a propane ...

Page 67: ...198 8 Install the outer shift fork and the shift fork shaft MD1327 9 Install the input driveshaft MD1326 10 Install the washer spacer sleeve and reverse idler gear MD1357 11 Install the secondary and primary driveshaft assemblies Account for the bearing alignment C ring on the bearing boss next to the driven gear NOTE Align the bearing alignment pin on the secondary output shaft Next Back Section ...

Page 68: ...ghten the 8 mm cap screws until the halves are correctly joined then tighten to 21 ft lb NOTE Rotate 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 binding or sticking occurs Installing Engine Transmission 1 From the right side place the engine transm...

Page 69: ...rter cable and secure with cap screws and nuts Tighten to 8 ft lb KC228A KC228B 6 Set the inlet air silencer into the frame then install the exhaust pipe using a new exhaust pipe seal and grafoil seal Tighten the cap screws evenly to 20 ft lb and install the muffler retainer springs KC237 KC238 Next Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 ...

Page 70: ...ghten all hose clamps securely KC254 9 Install the shift rod onto the shift arm with bushing and flat washer and secure with an E clip then connect the speedometer sensor plug KC255 KC248 10 Connect the oil temperature connector and cooling fan connector then using new O rings install the oil fittings onto the crankcase and secure with the cap screws Tighten to 8 ft lb KC249 KC250 Next Back Sectio...

Page 71: ...nt body panel front rack and foot wells see Section 8 14 Pour the appropriate quantity and grade oil into the crankcase then connect the negative battery cable and move the ATV outside to a well ventilated area 15 Start the engine and allow the engine to warm up while checking for oil leaks then shut the engine off and check the oil level Add oil as required Back Section Table of Contents Manual T...

Page 72: ...ions 4 2 Electric Choke 4 2 Carburetor 4 3 Throttle Cable Free Play 4 8 Engine RPM Idle 4 8 Gas Tank 4 9 Oil Filter Oil Pump 4 10 Testing Oil Pump Pressure 4 10 Oil Cooler 4 11 Troubleshooting 4 12 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 73: ... not to force the plunger from the carburetor body INSPECTING TESTING 1 Inspect the plunger A for scoring or scratches the needle B for damage to the tip the spring C for breakage and the O ring D for breaks KC328A 2 With the choke at room temperature approxi mately 70 F measure plunger extension Mea surement A should be 18 6 19 1 mm KC328B 3 Connect Electric Choke Test Harness to the choke connec...

Page 74: ...se KC256A KC263 KC264A WARNING Whenever any maintenance or inspection is per formed on the fuel system during which there may be fuel leakage there should be no welding smoking open flames etc in the area KEY 1 Cover 2 Screw 3 Spring 4 Vacuum Piston 5 Spring Seat 6 Jet Needle 7 Needle Jet 8 Jet Holder 9 Main Jet 10 Slow Jet 11 Starter Jet 12 Float Valve 13 Clip 14 Float 15 Float Pin 16 Pilot Screw...

Page 75: ...for a spring spring seat and the jet needle KC0021A 3 Remove the three screws securing the pump hous ing Account for the diaphragm assembly spring and U ring in the housing CC748 4 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring KC0022A KC0063A 5 Remove the float pin KC0024A 6 Lift the float assembly from the carburetor Account for the floa...

Page 76: ... air only making sure all holes orifices and channels are unobstructed 5 Inspect the carburetor body for cracks nicks stripped threads and any imperfections in the cast ing 6 Inspect the vacuum piston diaphragm for cracks imperfections in the casting or cracks and tears in the rubber 7 Inspect float for damage 8 Inspect gasket and O rings for distortion tears or noticeable damage 9 Inspect tips of...

Page 77: ...turns as an initial set ting NOTE Note the locations of the jets and holder during assembling procedures CC761A 3 Install the starter jet and slow jet Tighten securely KC0032A 4 Install the main jet into the needle jet holder and tighten securely then install the needle jet and needle jet holder assembly into the carburetor and tighten securely KC0031 KC0030A 5 Place the float assembly with float ...

Page 78: ...n securely CC748 8 Place the jet needle spring seat and spring into the vacuum piston then place the assembly down into the carburetor CC746 9 Place the top cover into position then secure with the Phillips head screws Tighten securely KC0019A INSTALLING 1 Connect the vent hose to the carburetor then con nect the electronic choke connector and install the throttle cable onto the throttle arm CAUTI...

Page 79: ...the air intake pipe then tighten the clamp securely KC245A KC256A 4 Connect the intake air housing and tighten all clamps and mounting hardware securely KC257 5 Install the gas tank see Gas Tank in this section Throttle Cable Free Play To adjust throttle cable free play see Section 2 Engine RPM Idle To adjust the idle RPM see Section 2 Next Back Section Table of Contents Manual Table of Contents F...

Page 80: ...e hose from the gas tank valve KC241A 6 Using a suitable block hold the front body open and remove 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 gas tank components with parts cleaning solvent 2 Inspect all hoses for cracks or leaks 3 Inspect tank c...

Page 81: ...nstall the gas tank cover and secure with the rein stallable rivets B KC219A 5 Install the side panels and seat making sure it locks securely in place Turn the gas tank valve to the ON position and check for leaks Oil Filter Oil Pump NOTE Whenever internal engine components wear excessively or break and whenever oil is con taminated the oil pump should be replaced The oil pump is not a serviceable...

Page 82: ...oil passage clogged oil filter or improper installation of the oil filter Oil Cooler 0743 004 REMOVING NOTE It is not necessary to drain the engine oil for this procedure 1 Remove the input and output hoses from the fit tings on the cooler 2 Remove the cap screws securing the oil cooler to the frame Account for grommets CAUTION Elevate and secure the hoses to avoid oil spillage KEY 1 Oil Cooler As...

Page 83: ...t 1 Clean tighten jet 2 Clean outlet 3 Adjust screw 4 Adjust float height 5 Adjust TPS 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 Vacuum piston not operating properly 5 Filter obstructed 6 Float height incorrect 1 Shift into higher gear decrease RPM speed 2 Clean main jet 3 Clean needle jet 4 Check p...

Page 84: ... Sensor 5 6 Ignition Switch 5 6 Handlebar Control Switches 5 7 Front Drive Selector Switch 5 7 Front Drive Selector Actuator 5 8 Gear Shift Position Switch 5 8 Stator Coil 5 9 Starter Relay 5 9 Starter Motor 5 10 CDI Unit 5 10 Regulator Rectifier 5 10 Neutral Start Front Drive Actuator Start in Gear 2WD Relays 5 11 Headlights 5 11 Taillights Brakelights 5 11 Running Lights 5 12 Back Up Lights 5 12...

Page 85: ...t that the battery is fully charged and that all appropriate switches are activated NOTE For absolute accuracy all tests should be made at room temperature of 68 F Accessory Receptacle Connector NOTE This test procedure is for either the recep tacle or the connector VOLTAGE 1 Turn the ignition switch to the ON position then set the meter selector to the DC Voltage position 2 Connect the red tester...

Page 86: ...leads selector in the OHMS position to the switch contacts 2 Suspend the switch and a thermometer in a con tainer of cooking oil then heat the oil NOTE Neither the switch nor the thermometer should be allowed to touch the bottom of the con tainer or inaccurate readings will occur Use wire holders to suspend switch and thermometer 733 554C 3 On the oil temperature switch when the oil temper ature r...

Page 87: ...he negative side The fan should operate Fuse Block Power Distribution Module The fuses are located in a power distribution module PDM in front of the steering tube If there is any type of electrical system failure always check the fuses first KC210A NOTE The ignition switch must be in the LIGHTS position 1 Remove all fuses from the distribution module 2 Set the meter selector to the DC Voltage pos...

Page 88: ...k Plug Cap 1 Connect the red tester lead to one end of the cap then connect the black tester lead to the other end of the cap AR603D 2 The meter reading must be within specification NOTE If the meter does not read as specified replace the spark plug cap PEAK VOLTAGE NOTE All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter If any other ...

Page 89: ...ing 3 Install the new speed sensor into the housing with new O ring lightly coated with multi purpose grease then secure the sensor with the cap screw threads coated with blue Loctite 242 Tighten securely CD071 Ignition Switch The ignition switch harness connects to the switch with a three pin connector To access the connector remove the access panel in front of the handlebar KC209 VOLTAGE NOTE Pe...

Page 90: ...t the meter selector to the OHMS position 2 Connect the one lead to the brown lavender wire then connect the other tester lead to the black white wire 3 With the switch in the OFF position the meter must show an open circuit 4 With the switch in the RUN position the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resistance replace the switch RESISTANCE Reverse Override ...

Page 91: ...he ignition switch to the ON position The meter must show 12 DC volts 4 Connect the red tester lead to the white blue wire in the supply harness The meter must show 12 DC volts 5 Select the 4WD position on the front drive selector switch then connect the red tester lead to the white blue wire in the supply harness The meter must show 0 DC volts NOTE The 4WD icon on the LCD should illumi nate 6 Con...

Page 92: ...ng Adapter If any other type of tester is used readings may vary due to internal circuitry NOTE The battery must be at full charge for this test Trigger Coil 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 blue wire 3 Crank the engine over using the electric starter 4 The meter reading must be within spec...

Page 93: ... then install the starter into the crank case Secure with two cap screws making sure the engine ground is secured by the rear cap screws Tighten to 8 ft lb KC201A 2 Secure the positive cable to the starter with the nut Tighten to 8 ft lb 3 Connect the battery CDI Unit The CDI is located on the electrical tray in front of the steering post NOTE The CDI unit is not a serviceable compo nent If the un...

Page 94: ...ter 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 v...

Page 95: ...released from the frame by depressing the release with a small screwdriver KC279 KC280 VOLTAGE 1 Release the wire connectors from the frame then disconnect the connectors NOTE Perform this test on the main harness side of the connectors 2 Connect the black tester lead to the brown laven der wire then connect the red tester lead to the lavender red wire 3 Set the tester to DC VOLTS then turn the ig...

Page 96: ...s shorted loose open 2 Magneto coils shorted grounded open 3 Regulator rectifier defective 1 Repair replace tighten lead wires 2 Replace magneto coils 3 Replace regulator rectifier Problem Magneto charges but charging rate is below the specification Condition Remedy 1 Lead wires shorted open loose at terminals 2 Stator coils magneto grounded open 3 Regulator rectifier defective 4 Electrolyte low 5...

Page 97: ...taminated 1 Replace battery 2 Keep electrolyte to prescribed level 3 Charge battery add distilled water 4 Replace battery 5 Replace battery Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Specific gravity too low 3 Charging system not charging 4 Cell plates overcharged damaged 5 Battery short circuited 6 Specific gravity too low 1 Replace battery 2 Charge batte...

Page 98: ...r 6 2 Front Differential 6 3 Drive Axles 6 13 Rear Gear Case 6 17 Hub 6 18 Hydraulic Brake Caliper 6 19 Troubleshooting Drive System 6 22 Troubleshooting Brake System 6 22 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 99: ...the front drive input housing With the engine stopped and the ignition switch in the ON position a momentary whirring sound can be heard each time the front drive selector switch is shifted If no sound is heard see Sec tion 5 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 Remove the ...

Page 100: ...witch to the ON position and check the operation by shifting the selector switch several times 7 Secure the wiring harness to the frame with a nylon cable tie Front Differential REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the drain plug and drain the gear lubricant into a drain pan then reinstall the plug and tighten to 45 in lb ATV0082A 3 Remove the fr...

Page 101: ... may vary from model to model The technician should use discretion and sound judgment 1 Remove the cap screws securing the front drive actuator and remove the actuator then remove the cap screws securing the pinion housing CD102 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for assembling purposes CAUTION A...

Page 102: ...on housing CD107 5 Using a seal removal tool remove the input shaft seal Account for a spacer AF982 6 Remove the snap ring securing the input shaft bearing then place the pinion housing in a press and remove the bearing AF983 AF984 KX219 Next Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 103: ...se KX221 KX222 4 Install the input shaft into the housing then install the front boot and secure with an appropriate boot clamp and the rear 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 onto the gear case housing then secure with the existing cap screw...

Page 104: ... and account for a shim Mark the shim as left side KX177 KX178 5 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s and mark as right side KX179 KX181 6 Using the 48 mm Internal Hex Socket remove the lock collar securing the pinion gear assembly NOTE On a front differential the lock collar has right hand threads On a rear gear case the l...

Page 105: ...he 0 category NOTE If the gear case housing is being replaced proceed to the following Shimming Proce dure Shim Selection sub section Shimming Procedure Shim Selection 1 Press bearings into bores by outer ring to hard con tact with seat 2 Install the lock collar and tighten to 125 ft lb then on final assembling stake the lock collar edge approximately 1 5 mm into the lower oil channel CC891 3 Note...

Page 106: ... the bearing using a press CC884 3 Install the pinion gear assembly into the housing Using the 48 mm Internal Hex Socket secure the pinion gear assembly with the existing lock collar Tighten to 125 ft lb NOTE On a front differential the lock collar has right hand threads On a rear gear case the lock collar has left hand threads CC890 4 Place a punch on the edge of the lock collar in the oil galler...

Page 107: ...irmly into the cover CF267A 10 Apply a liberal amount of grease to the O ring then install it on the assembled cover assembly making sure to seat the O ring down around the circumference of the bearing flange 11 Making sure the O ring is properly positioned on the gear case cover assembly install the cover with existing hardware Account for the ID tag Tighten the cap screws to 18 ft lb NOTE Grease...

Page 108: ...f a new bearing then place the new bearing into the hous ing CC888 2 Using a suitable driver install the needle bearing into the gear case housing making sure the bearing is seated NOTE Do not push the bearing too far into the housing CC889 3 Install the pinion shaft and secure with the existing 48 mm lock collar Tighten to 125 ft lb CC890 4 Place a punch on the edge of the lock collar in the oil ...

Page 109: ...llation tool evenly press the seal into the cover bore until seated CF278 5 Repeat steps 1 4 for the opposite side INSTALLING DIFFERENTIAL 1 Align the input flange with the front output flange then place the differential into position on the frame and install the cap screws and nuts Tighten to 38 ft lb KC291A 2 Install the cap screws securing the flange couplers together and tighten to 20 ft lb CA...

Page 110: ...ex nut Release the brake lever lock 5 Remove the brake caliper right side only NOTE Do not allow the brake caliper to hang from the hose 6 Slide the hub off the shaft and set aside 7 Remove the cap screw and lock nut securing the knuckle to the upper A arm Discard the lock nut KC284 NOTE Never reuse a lock nut Once a lock nut has been removed it must be replaced with a new lock nut 8 While holding...

Page 111: ...t be replaced with a boot kit 3 Inspect the gear case seals for nicks or damage DISASSEMBLING AXLES 1 Using a side cutters or suitable substitute remove the large clamp from the boot CD020 2 Wipe away excess grease to access the retaining ring Using an awl remove the circlip CD021 3 Using a snap ring pliers remove the snap ring securing the bearing ring to the shaft Note the direction of the beari...

Page 112: ...s 120 grams of grease The inside joint double offset requires approximately 70 90 grams of grease and the out side bell type requires approximately 35 55 grams When replacing boots use 2 3 of the pack for inside boots and 1 3 of the pack for outside boots 9 Slide the new outside boot onto the shaft with the new clamps positioned as shown Note the differ ent sized clamps from removal NOTE The boot ...

Page 113: ...aces away from the boot CD023 6 Making sure the marks made during disassembling align slide the housing over the bearing ring then completely seat the bearing ring into the housing and install the circlip NOTE Pull the bearing ring out of the housing until it contacts the circlip then slide the ring in half way This will purge air from the housing and ensure the bearing is packed properly CD021 7 ...

Page 114: ...emove the ATV from the support stand and release the brake lever lock INSTALLING FRONT DRIVE AXLE 1 Position the drive axle in the gear case and steer ing knuckle then insert the upper A arm ball joint into the steering knuckle Secure with a cap screw tightened to 35 ft lb 2 Slide the hub w brake disc into position in the steering knuckle followed by a washer and hex nut Tighten finger tight at th...

Page 115: ...ively cracked or damaged in any way replacement is necessary 1 Clean all hub components 2 Inspect all threads for stripping or damage 3 Inspect the brake disc for cracks or warping 4 Inspect the hub for pits cracks loose studs or spline wear INSTALLING 1 Secure the brake disc to the hub with the four cap screws coated with blue Loctite 243 Tighten to 15 ft lb 2 Apply grease to the splines in the h...

Page 116: ...e caliper holder against the caliper opposite the O ring side and remove the outer brake pad then remove 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 discard the O ring WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake se...

Page 117: ...s see Section 2 3 Inspect the brake caliper housings for scoring in the piston bores chipped seal ring grooves or signs of corrosion or discoloration 4 Inspect the piston surface for scoring discolor ation or evidence of binding or galling 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 br...

Page 118: ...ce a new crush washer on each side of the brake hose fitting and install it on the caliper Tighten to 20 ft lb 8 Fill the reservoir then bleed the brake system see Section 2 9 Install the wheel Tighten to 40 ft lb 10 Remove the ATV from the support stand and ver ify brake operation CAUTION If brake pads become contaminated with brake fluid they must be thoroughly cleaned with brake cleaning solven...

Page 119: ...lace gear s 8 Replace axle 9 Replace axle Problem Braking poor Condition Remedy 1 Pad worn 2 Pedal free play excessive 3 Brake fluid leaking 4 Hydraulic system spongy 5 Master cylinder brake cylinder seal worn 1 Replace pads 2 Replace pads 3 Repair replace hydraulic system component s 4 Bleed hydraulic system correct or repair leaks 5 Replace master cylinder Problem Brake lever travel excessive Co...

Page 120: ...OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 2 Rear A Arms 7 3 Wheels and Tires 7 4 Troubleshooting 7 6 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 121: ... on a support stand to elevate the front wheels then remove the wheels 2 Remove the cotter pin from the nut Discard the cotter pin 3 Remove the nut securing the hub 4 Remove the brake caliper Account for two cap screws KC187A 5 Remove the hub assembly 6 Remove the cap screws securing the ball joints to the knuckle KC313A 7 Tap the ball joints out of the knuckle then free the knuckle from the axle ...

Page 122: ... secure with cap screws Tighten to 35 ft lb 6 Apply grease to the hub and drive axle 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 Tighten to 20 ft lb 9 Secure the hub nut from step 7 to the shaft axle Tighten to 200 ft lb 10 Install a new cotter p...

Page 123: ...in and spread the pin to secure the nut 9 Secure the shock absorber to the frame with a cap screw and new lock nut Tighten to 35 ft lb 10 Secure the shock absorber to the lower A arm with a cap screw and new lock nut Tighten to 20 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 suppor...

Page 124: ...ure 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 Test drive the ATV on a dry level surface and note any pulling to the left or right during acceleration deceleration and braking NOTE If pulling is noted measure the circumfer ence of the front and rear tires on the pulling side Compare the measur...

Page 125: ...arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Rear wheel oscillation Condition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Auxiliary brake adjusted incorrectly 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 1 Replace bearings 2 Repla...

Page 126: ...rip 8 3 Steering Knuckles 8 4 Measuring Adjusting Toe In 8 5 Front Rack 8 6 Front Bumper Assembly 8 6 Front Body Panel Fender 8 7 Exhaust System 8 8 Rear Body Panel Rack 8 9 Troubleshooting 8 11 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 127: ...ower steering post to the bearing Account for a flat washer KC184B 6 Remove the steering post from the ATV CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Wash the tie rod ends in parts cleaning solvent Dry with compressed air Inspect the pivot area for wear Apply a low temperature grease to the ends 2 Inspect the tie rods f...

Page 128: ... to 30 ft lb then install new cotter pins KC184A 4 Place the handlebar and caps in place on the steer ing post and with the handlebar correctly posi tioned tighten the cap screws to 20 ft lb KC0058 5 Install the steering post cover then install the front body panel fender see Front Body Panel Fender in this section Handlebar Grip REMOVING 1 Loosen but do not remove the cap screw in the end of the ...

Page 129: ...r pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then remove the knuckle 9 Remove the snap ring from the knuckle then remove the bearing PR287A PR288 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necess...

Page 130: ... In 1 Thoroughly wash the ATV to remove excess weight mud etc 2 Refer to the specifications and ensure the tires are properly inflated to the recommended pressure NOTE Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur 3 Place the ATV in a level position taking care not to push down or lift up on the front end then turn the handlebar to the straight ahead po...

Page 131: ... bending 3 Inspect threaded areas of all mounting bosses for stripping 4 Inspect for missing decals and or reflectors INSTALLING 1 Place the rack into position on the frame and front fender panel Install the cap screws and lock nuts and finger tighten only 2 Install the two cap screws and lock nuts securing the rack to the fenders Tighten all hardware securely Front Bumper Assembly REMOVING 1 Remo...

Page 132: ... remove the rein stallable rivets B and remove the tank cover KC219A KC220 4 Remove the shift knob then remove the shift mechanism splash shield KC211 5 Remove the screws securing the front body to the front body supports then remove the left side and right side footwell fasteners KC204A 6 Remove the electric panel then disconnect the LCD gauge connector ignition switch and acces sory outlet Next ...

Page 133: ... footwell fasteners Do not tighten at this time 4 Place the gas tank cover into position and secure with the existing hardware then install the two cap screws securing the rear of the panel to the frame Tighten all cap screws and fasteners securely at this time 5 Install the electric panel side panels and seat Exhaust System REMOVING MUFFLER 1 Remove the two exhaust springs at the muf fler exhaust...

Page 134: ...C317A KC316 2 Disconnect the battery negative cable first and remove from the battery compartment then dis connect the starter relay wires and route the wiring out of the compartment KC322A 3 Remove the auxiliary brake reservoir from the body but do not disconnect the hose then route and secure the hose and reservoir out of the way making sure not to spill brake fluid KC306 4 Using a small screwdr...

Page 135: ...nder in place on the ATV then secure with the cap screws on the side frame and the rear rack assembly Tighten all fas teners 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 positive cables first KC279 KC322 3 Secure the rear fenders to the footwells and tighten the...

Page 136: ... 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 replace frame 5 Replace shock absorber Problem Tire wear rapid or uneven Conditi...

Page 137: ...S INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 2 LCD Gauge 9 3 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 138: ... pivot hole 3 Inspect the reservoir for cracks and leakage 4 Inspect the banjo fitting and bolt for cracks and deterioration and the condition of the fittings threaded and compression INSTALLING 1 Position the brake housing on the handlebar Secure with clamp screws then tighten securely 2 Using two new crush washers connect the banjo fitting to the master cylinder then secure with the banjo fittin...

Page 139: ... ADJUSTING To adjust throttle cable free play see Section 2 LCD Gauge REPLACING To replace the LCD gauge use the following proce dure 1 Remove the electric panel and disconnect the LCD gauge connector then remove three mounting screws two in front and one in back of gauge and remove the gauge KC210G KC323A 2 Install the new gauge and secure with the mount ing screws then connect the gauge to the m...