Arctic Cat 2011 366 SE, Service Manual

Page 1: ...nt to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal 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 NO...

Page 2: ...ems 16 Troubleshooting 84 Burnishing Brake Pads 18 Drive System 86 Checking Replacing V Belt 18 Front Drive Actuator 86 Engine Transmission 21 Front Differential 87 Specifications 21 Drive Axles 98 Troubleshooting 22 Rear Gear Case 102 Removing Engine Transmission 24 Hub 102 Top Side Components 26 Hydraulic Brake Caliper 103 Removing Top Side Components 26 Troubleshooting Drive System 106 Servicin...

Page 3: ...1 STEERING COMPONENTS Steering Post Bearing Housing Frame 20 27 Handlebar Cap Steering Post 20 27 Lower Steering Post Bearing Cap Screw Steering Post 40 54 Tie Rod End Steering Post Arm 30 41 BRAKE COMPONENTS Brake Disc Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Brake Hose Auxiliary Brake Cylinder 20 27 Master Cylinder Rear Frame 8 11 Master Cylinder Clamp Front Master Cyl...

Page 4: ...er Crankcase 8 11 Crankcase Half 6 mm Crankcase Half 10 13 5 Crankcase Half 8 mm Crankcase Half 21 28 Cylinder Nut Crankcase Half 8 11 Cylinder Head Cap Screw Crankcase 28 38 Cylinder Head Nut Cylinder 20 27 Cylinder Head 6 mm Cylinder 8 11 Cylinder Head 8 mm Cylinder 20 27 Cylinder Head Cover Cylinder Head 8 11 Oil Pump Drive Gear Crankshaft 63 86 Driven Pulley Nut Driveshaft 147 199 Ground Cable...

Page 5: ...is lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives FILLING GAS TANK Since gasoline expands as its temperature rises the gas tank must be filled to its rated capacity only Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area ATV0049B Tighten the gas tank cap sec...

Page 6: ...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 recommends the following procedure to pre pare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the muffler 3 Check all control cables for signs of wear or fraying Replace if nec...

Page 7: ...Initial Service After Break In First Mo or 100 Mi Every Day Every Month or 100 Miles Every 3 Months or 300 Miles Every 6 Months or 500 Miles Every Year or 1500 Miles As Needed Battery I I C Fuses I R Air Filter Drain Tube I I C R Valve Tappet Clearance I I A Engine Compression I Spark Plug I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R Gas Vent Hoses I I R 2 Yrs Throttle Cable I I C L A R Carbu...

Page 8: ...n dip the element in the solvent and wash it NOTE Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat 4 Dry the element 5 Put the element in a plastic bag then pour in air filter oil and work the oil into the element Insert the form ing spring into the element with the closely wrapped end of the spring toward the open end of the element 6 Clean any dirt or debris from ins...

Page 9: ...Top Side Components CF005 2 Rotate the crankshaft to the TDC position on the compression stroke NOTE At this point the rocker arms and adjuster screws must not have pressure on them Feeler Gauge Procedure Using a feeler gauge check each valve tappet clearance If clearance is not within specifications loosen the jam nut and rotate the tappet adjuster screw until the clear ance is within specificati...

Page 10: ...wing procedure 1 Remove the high tension lead from the spark plug 2 Using compressed air blow any debris from around the spark plug 3 Remove the spark plug then attach the high tension lead to the plug and ground the 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 Whi...

Page 11: ... from the screen taking care not to 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 adj...

Page 12: ...lter to drain completely Install the plug and tighten securely 6 Using the adjustable Oil Filter Wrench and a suitable wrench remove the old oil filter NOTE Clean up any excess oil after removing the filter 7 Apply oil to a new filter seal ring and check to make sure it is positioned correctly then install the new oil filter Tighten securely 8 Install the engine drain plug and tighten to 20 ft lb ...

Page 13: ...nk case and secure with the cap 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 ...

Page 14: ...ged or worn Nuts Bolts Cap Screws Tighten all nuts bolts and cap 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 Ignition Timing The ignition timing cannot be adjusted however verify ing ignition timing can aid in troubleshooting other com ponents To verify igniti...

Page 15: ...e the wiring har ness connector from the back of the headlight bulb KC146A KC162 2 Press in and release the spring retainer and pull rear ward clear of the bulb assembly KC163A 3 Remove the headlight bulb assembly from the head light housing 4 Install the new headlight bulb into the headlight housing being careful not to get fingerprints or other contaminates on the glass then secure with the spri...

Page 16: ...eometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the ATV on a level floor so the headlights are approximately 6 1 m 20 ft from an aiming sur face wall or similar aiming surface ATV 0070C NOTE There should be an average operating load on the ATV when adjusting the headlight aim 2 Measure the distance from the floor to the mid point of each head...

Page 17: ...osen jam nut C and with the shift lever in the reverse position adjust the coupler B until the transmission is in reverse and the R icon appears on the LCD KC194A 3 Tighten the jam nuts securely then shift the trans mission to each position and verify correct adjust ment 4 Install the left side engine cover and seat making sure the seat locks securely in place Frame Welds Racks The frame welds and...

Page 18: ...follow the same proce dure 4 Carefully check the entire hydraulic brake system that all hose connections are tight the bleed screws are tight the protective caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKING REPLACING PADS The clearance between the brake pads and bra...

Page 19: ... brake system twenty times 4 Adjust the auxiliary brake if necessary 5 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed Checking Replacing V Belt REMOVING 1 Remove the seat and right side engine cover then remove the cap screw securing the auxiliary brake pedal to the frame Account for a flat washer KC149A 2 Slide the auxiliary brake pedal pa...

Page 20: ...ing cracks or grooving then clean any dirt and debris from the V belt housing and cover INSTALLING 1 Place the V belt onto the driven pulley making sure the arrows 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...

Page 21: ...ins installed in the V belt housing and a new V belt cover 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 Manual Table of Contents ...

Page 22: ...ter intake exhaust 4 975 4 990 mm 4 955 4 970 mm Valve Stem Runout max 0 05 mm Valve Head Thickness min 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 CAMSHAFT AND CYLINDER HEAD Cam Lobe Height...

Page 23: ...rburetor 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 Valve clearance too large 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 5 Valve tappets worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replac...

Page 24: ... Adjust float height 8 Clean element 9 Clean or replace hose 10 Replace fuel pump Problem Exhaust smoke dirty or heavy Condition Remedy 1 Oil in the engine overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored scuffed 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil replace oil 2 Replace service rings cylinder 3 Replace cylinder head 4 Replace ...

Page 25: ...250 KC249 4 Disconnect the speedometer sensor then remove the E clip securing the shift rod to the shift arm and disconnect the shift rod Account for a bushing and flat washer KC248 KC255 5 Remove the inlet air duct air filter housing and air silencer duct then remove the carburetor and set aside leaving the throttle cable attached AT THIS POINT If the technician s objective is to service Top Side...

Page 26: ...eal ring KC170 KC238 7 Disconnect the gear position switch starter cable and engine ground cable then disconnect the trigger coil and stator coil connectors KC228C KC228B 8 Remove the front and rear V belt cooling boots from the V belt housing 9 Remove the cap screws from the front and rear out put flanges then remove the front and rear engine mounting through bolts KC242 Manual Table of Contents ...

Page 27: ... an appro priate wrench rotate the crankshaft to top dead cen ter of the compression stroke NOTE Arctic Cat recommends the use of new gas kets lock nuts and seals and lubricating all internal components when servicing the engine transmis sion 1 Remove the cap screws securing the two tappet cov ers Remove the two tappet covers Account for the O rings MD1264 NOTE Keep the mounting hardware with the ...

Page 28: ... camshaft MD1136 MD1137 6 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken not to drop the C ring down into the crankcase MD1131 7 Noting the timing marks for installing purposes drop the sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cyl inder head Account for an ali...

Page 29: ...the left spark plug side CD211 10 Remove the cylinder head from the cylinder remove the gasket and account for two alignment pins MD1163 11 Remove the cam chain guide MD1173 C Cylinder D Piston NOTE Steps 1 11 in the preceding sub section must precede this procedure 12 Remove the two nuts securing the right side of the cylinder to the right side crankcase half KC337A AT THIS POINT To service valve...

Page 30: ...ne end of the ring out of the ring groove B Remove each ring by working it toward the dome of the piston while rotating it out of the groove Servicing Top Side Components NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve faces and valve stem ends for pits burn marks or ...

Page 31: ...pring compressor compress the valve springs and remove the valve keepers Account for an upper spring retainer CC994 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC134D CC136D NOTE The valve seals must be replaced 3 Remove the valve springs then invert the cylinder head and remove the valves Measuring Valve Stem Runout 1 Support each valve stem end with the V B...

Page 32: ...uring Valve Guide Inside Diameter 1 Insert a snap gauge 1 2 way down into each valve guide bore then remove the gauge and measure it with a micrometer 2 Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance the cylinder head must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replaceme...

Page 33: ...excessive carbon in ring grooves or an out of round cylinder Removing Piston Rings 1 Starting with the top ring slide one end of the ring out of the ring groove CC400D 2 Remove each ring by working it toward the top 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 n...

Page 34: ...the corresponding piston diameter at a point 15 mm 0 6 in above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measurement in step 1 The difference clearance must be within specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends ...

Page 35: ...uge check the distortion between the head and the straightedge 3 Maximum distortion must not exceed specifications CC141D Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting scoring scuffing warpage and corrosion If marks are found repair the surface using a cylinder hone see Honing Cylin der in this sub section 3 Place the cylinder on the ...

Page 36: ...produce the proper 60 cross hatch pat tern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not available use a lightweight petroleum based oil Thoroughly clean cylinder after honing using soap and hot water Dry with compressed air then immediately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder CC390D 4 If any measurem...

Page 37: ... 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve cover and cam shaft MD1261 5 Match the width of the plasti gauge with the chart found on the plasti gauge packaging to determine camshaft to cylinder head and valve cover clearance CC145D 6 If clearance is excessive measure the journals of the camshaft CC287D NOTE If the journals are worn replace the cam shaft ...

Page 38: ...lder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase MD1344 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crankcase MD1345...

Page 39: ...lug side Tighten only until snug MD1270 8 Install the two lower nuts securing the cylinder head to the cylinder one in front and one in rear MD1192 9 In a crisscross pattern tighten the four cylinder head cap screws from step 7 to 28 ft lb Tighten the two lower cylinder head nuts from step 8 to 20 ft lb and the cylinder to crankcase nuts from step 4 to 8 ft lb 10 With the timing inspection plug re...

Page 40: ...ust be parallel with the valve cover mating surface If rotating the cam shaft is necessary for alignment do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position 15 When the camshaft assembly is seated ensure the following A Piston still at top dead center B Camshaft lobes directed down toward the pis ton C Camshaft alignment marks parallel to the valve c...

Page 41: ...ing loaded lock and push the plunger into the tensioner MD1146 23 Place the cam chain tensioner assembly and gasket into the cylinder making sure the ratchet side is fac ing toward the top of the cylinder and secure with the two cap screws MD1254 24 Install the cap screw and spring into the end of the cam chain tensioner Tighten securely MD1245 25 Loosen the adjuster screw jam nuts then loosen the...

Page 42: ...es not have to be removed from the frame for this procedure Removing Left Side Components A Cover Stator Assembly 1 Remove the cap screws securing the outer magneto cover and remove the cover 2 Remove the left side cover to crankcase mounting cap screws noting the location of the 8 mm cap screw with the washer near the middle of the left side cover Keep the different lengthed 6 mm cap screws in or...

Page 43: ...Using Magneto Rotor Remover break the rotor fly wheel assembly loose from the crankshaft Remove the remover the crankshaft protector the rotor fly wheel and the starter clutch gear Account for the key MD1368 MD1369 MD1370 7 Remove the starter idler gear No 1 and starter idler gear No 2 MD1305 8 Remove the gear shift shaft assembly and washer from the left side crankcase Note the positions of the a...

Page 44: ...ve the crankshaft bearing retainer MD1122 Installing Left Side Components A Starter Idler Gears B Rotor Flywheel 1 Place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three cap screws securely MD1122 2 Install the starter motor and tighten the two cap screws to 8 ft lb 3 Install the shift detent cam making sure the washer is pro...

Page 45: ... addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A V Belt Cover B Driven Pulley C Clutch Cover 1 If the engine is still in the frame remove the cap screw securing the brake pedal to the pivot shaft Account for a flat washer...

Page 46: ...ssembly MD1068 8 Using an impact screwdriver remove the three Phil lips head cap screws holding the air intake plate Remove the air intake plate MD1092 9 Remove the cap screws holding the clutch cover onto the right side crankcase half Note the positions of the different lengthed cap screws for installing pur poses 10 Using a rubber mallet loosen the clutch cover then pull it away from the right s...

Page 47: ... onto the right side crankcase half KC324A 12 Remove the gear position switch Account for a spacer KC326A 13 Remove the one way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes MD1286 14 Remove the left hand threaded nut holding the cen trifugal clutch assembly MD1014 MD1016 15 Remove the cam chain CAUTION Care must be taken when removing the nut it has left...

Page 48: ... and thrust washer MD1020 H Oil Pump Oil Strainer NOTE Steps 1 19 in the preceding sub sections must precede this procedure 20 Remove three Phillips head screws holding 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 CC091D AT ...

Page 49: ...he word OUTSIDE 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 hous ing counterclockwise to properly seat the one way clutch KC331A 3 Check that the clutch shoe can only be rotated coun terclockwise in respect to the clutch housing If the clutch shoe locks up or turns either direction the one wa...

Page 50: ...208 3 Place two alignment pins and the oil pump into posi tion on the crankcase and secure with the Phillips 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 ...

Page 51: ...the crankcase MD1286 9 Install gear position switch spacer and switch mak ing 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...

Page 52: ...belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V belt to drop into the pulley approximately 3 4 in KC137 NOTE The arrows on the V belt should point in direction of engine rotation 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 ...

Page 53: ...e this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those 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 purpo...

Page 54: ...move the reverse idler gear spacer and sleeve Account for the 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 shi...

Page 55: ...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 acceptable range no correction is necessary 1 If backlash measurement is less than specified remove a...

Page 56: ... 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 CC290D 2 Maximum diameter must not exceed specifications Measuring Connecting Rod Small End Deflection 1 Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate Position the indicator contact point against the ...

Page 57: ...t for the bushing and bear ing 4 Remove the washer then remove the circlip securing the sliding dog Remove the sliding dog 5 Remove the high driven gear circlip then remove the high driven gear Account for the washer bushing and bearing Assembling 1 Place the high driven gear onto the countershaft making sure the bearing bushing and washer are properly positioned Secure with the circlip 2 Place th...

Page 58: ...pply a liberal amount of oil to the crankshaft bear ing Using a propane torch heat the bearing until the oil begins to smoke then slide the crankshaft assem bly into place MD1334 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft installer 4 Rotate the crankshaft so the counterweight is toward the rear of the engine Install the counterbalance shaft MD102...

Page 59: ...idler gear MD1357 11 Install the secondary and primary driveshaft assem blies Account for the bearing alignment C ring on the bearing boss next to the driven gear NOTE Align the bearing alignment pin on the sec ondary output shaft Joining Crankcase Halves 1 Verify that the two alignment pins are in place and that both case halves are clean and grease free Apply Three Bond Sealant to the mating sur...

Page 60: ...ticking 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 transmission into the frame tilting the top side forward to clear the frame member KC216 2 Install the front and rear engine mounting through bolts and secure...

Page 61: ...et 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 KC170 7 Place the carburetor into the intake pipe being care ful to align the lug on the carburetor with the align ment tabs on the air intake pipe then tighten the clamp securely Manual ...

Page 62: ... KC254 9 Install the shift rod onto the shift arm with bushing and flat washer and secure with an E clip then con nect 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 KC251 Manual Table of Contents ...

Page 63: ... the gas tank see Fuel Lubrication Cooling 13 Install the front body panel front rack and footwells see Steering Frame 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 ...

Page 64: ... approximately 70 F measure plunger extension Measurement A should be 18 6 19 1 mm KC328B 3 Connect Electric Choke Test Harness to the choke connector and a suitable 12 DC volt power supply for 2 3 minutes Disconnect the power and measure plunger extension Measurement B should be 22 1 23 4 mm KC328C 4 If the choke is damaged or the measurements are not within specifications the choke must be repla...

Page 65: ...or can now be removed for service KC258A WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leak age 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 ...

Page 66: ...securing the pump housing 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 float valve and clip KC0025A NOTE Note the locations of the jets pilot screw and ho...

Page 67: ...ds 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 the jet needle pilot screw and the needle jet for wear damage or distortion 10 Inspect the slow jet and main jet for obstructions o...

Page 68: ... jet into the needle jet holder and tighten securely then install the needle jet and nee dle jet holder assembly into the carburetor and tighten securely KC0031 KC0030A 5 Place the float assembly with float valve into posi tion and secure to the carburetor with the float pin KC0024 NOTE Check float height by placing the carburetor on its side w float contacting the needle then mea sure with a cali...

Page 69: ...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 connect the electronic choke connector and install the throttle cable onto the throttle arm CAUTION It is important to press down on the pump hou...

Page 70: ...gnment lug on the carburetor is between the two tabs on 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 Periodic Mainte nance Engine RPM Idle To adjust the idle RPM see Peri...

Page 71: ...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 nec essary 1 Clean all gas tank components with parts cleaning solvent 2 Inspect all hoses for cracks or leaks 3 Inspect tank cap and tank...

Page 72: ... tank cover and secure with the reinstallable 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 contami nated the oil pump should be replaced The oil pump is not a serviceable component Test...

Page 73: ...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 fittings on the cooler 2 Remove the cap screws securing the oil cooler to the frame Account for grommets AL651D 3 Remove the oil cooler from the frame INSTALLING 1 Place the cooler into position in the frame 2 Secure the cooler to the frame with the c...

Page 74: ...t 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 piston operation 5 Clean filter 6 Adjust float height Problem Over...

Page 75: ... as specified the battery may be returned to service see step 10 7 If the meter reads less than specified voltage charge the battery using the following guidelines A When using an automatic battery charger always follow the charger manufacturer s instructions B When using a constant current battery charger use the following Battery Charging Chart Description p n Fluke Model 73 Multimeter 0644 191 ...

Page 76: ...ting a specific component always verify first that the fuse s are good that the bulb s are good that the connections are clean and tight 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 recepta cle or the connecto...

Page 77: ...er or inaccurate readings will occur Use wire holders to suspend switch and thermometer 733 554C 3 On the oil temperature switch when the oil tempera ture reaches 160 C 320 F the meter should read a closed circuit 4 On the oil temperature switch allow the oil to cool and when the temperature is at or just before a tem perature of 140 C 284 F the meter should read an open circuit 5 On the cooling f...

Page 78: ...se compress the locking tabs on either side of the fuse case and lift out 0411 837 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 position 3 Connect the black tester lead to ground 4 Using the red tester lead contact each end of the fuse holder connector terminals individually 5 The meter mus...

Page 79: ...d 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 or Fluke Model 77 Multimeter with Peak Voltage Reading Adapter If any other type of tester is used readings may vary due to internal circuitry ...

Page 80: ...ector to the DC Voltage position 2 Connect the red meter lead to the red white wire then connect the black meter lead to ground 3 Meter must show battery voltage NOTE If the meter shows no battery voltage trou bleshoot the battery or the main wiring harness RESISTANCE NOTE Perform this test on the switch harness using the following procedure KC276A 1 Turn the ignition switch to the ON position 2 S...

Page 81: ...selector switch in the 4WD position the meter must show an open circuit NOTE If the meter does not show as specified replace the front drive selector switch VOLTAGE NOTE The battery must be connected when per forming voltage tests 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the negative battery terminal 3 Connect the red tester lead to the brown lavender ...

Page 82: ... the AC Voltage position 2 Test between the three black wires for a total of three tests 3 With the engine running at the specified RPM all wire tests must show 60 AC volts NOTE If both charging coil tests failed check all connections etc and test again If no voltage is present replace the stator assembly RESISTANCE Charging Coil 1 Set the meter selector to OHMS position 2 Test between the three b...

Page 83: ... operate AR607D NOTE If the meter showed correct voltage but the starter did not operate or operated slowly the starter motor is defective NOTE If the meter showed no voltage inspect ground connections starter motor lead battery voltage at the battery starter relay or the neutral start relay REMOVING 1 Disconnect the battery 2 Remove the nut securing the positive cable to the starter then remove t...

Page 84: ... must show battery voltage 4 Remove the red tester lead from the white wire and connect to the lavender wire 5 With the dimmer switch in the HI position the meter must show battery voltage NOTE If battery voltage is not shown in any test inspect the fuses battery main wiring harness con nectors or the left handlebar switch Voltage Running Lights 1 Release the wire connector from the frame then rel...

Page 85: ...ve the black tester lead from the brown laven der wire and connect to a suitable ground A If the meter shows battery voltage troubleshoot the gear shift position switch connector or the gear shift position switch B If the meter does not show battery voltage inspect the LIGHTS fuse ignition switch or the main wiring harness Ignition Timing The ignition timing cannot be adjusted however verifying ig...

Page 86: ... defective 1 Replace lead wire 2 Replace magneto 3 Replace regulator rectifier Problem Starter button not effective Condition Remedy 1 Battery charge low 2 Switch contacts defective 3 Starter motor brushes not seating 4 Starter relay defective 5 Emergency stop ignition switch off 6 Wiring connections loose disconnected 1 Charge replace battery 2 Replace switch 3 Replace starter motor 4 Replace rel...

Page 87: ... sound is heard see Electrical System If the actuator runs constantly or makes squeal ing or grinding sounds the actuator must be replaced REMOVING 1 Disconnect the connector on the actuator harness 2 Remove the mounting cap screw from the driveshaft side of the actuator KC293A 3 Remove the mounting cap screw from below the actuator on the suspension side KC294A 4 Loosen but do not remove the moun...

Page 88: ...h 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 front wheels 4 Pump up the hand brake then engage the brake lever lock 5 Remove t...

Page 89: ... be performed on a rear gear case however some components may vary from model to model The technician should use dis cretion and sound judgment 1 Remove the cap screws securing the front drive actu ator 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 locat...

Page 90: ...ve the input shaft seal Account for a spacer AF982 6 Remove the snap ring securing the input shaft bear ing then place the pinion housing in a press and remove the bearing AF983 AF984 KX219 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside A...

Page 91: ...riate 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 screws Tighten to 18 ft lb CD103 Disassembling Pinion Gear NOTE This procedure can be performed on a rear gear case ...

Page 92: ...179 KX181 5 Unstake the lock collar then using the 48 mm Inter nal Hex Socket remove the lock collar securing the pinion gear assembly NOTE On a front differential the lock collar has right hand threads On a rear gear case the lock col lar has left hand threads CC875 CC876 6 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing CAUTION Failure to c...

Page 93: ...ceeding Backlash NOTE Always set backlash prior to any other shimming 1 Install the existing shim or a 0 051 0 055 in shim on the gear case side of the ring gear assembly GC031A 2 Install the ring gear with shim in the gear case then while holding the pinion stationary rock the ring gear forward and back to determine if any backlash exists If no backlash exists install a thicker shim and recheck G...

Page 94: ...re the gear case in a holding fixture with the cover side up then install a dial indicator contacting the ring gear axle flange GC065 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008 in 3 To increase end play decrease the shim thickness To decrease end play increase the shim thickness NOTE Once proper backlash and end play are e...

Page 95: ...ash shim on the gear case side of the ring gear with the chamfered side toward the ring gear then install into gear case differential housing GC031A GC059 2 Place the selected end play shim chamfered side toward the gear onto the cover side of the ring gear GC059B NOTE The spider and ring gear assembly must be replaced as a complete unit 3 Making sure the O ring is properly positioned on the diffe...

Page 96: ...an be performed on a rear gear case 1 Place a 1 4 in drill bit on the inside surface of the needle bearing against the bottom side then drill through the pinion shaft needle bearing housing CC885 2 Using a propane torch heat the area surrounding the needle bearing to soften the Loctite CC886 3 Using a flat nosed punch drive the bearing out of the housing CC887 Installing Needle Bearing 1 Apply gre...

Page 97: ... CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock col lar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool GC066 2 Using a press remove the bearing CC900 3 Using a...

Page 98: ...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 AG925 3 Install the front axles see Drive Axles in this sec tion AF610D AF897D 4 Install the brake calipers and secure with the patch lock cap screws tightened to 20 ft lb AF894D 5 Install...

Page 99: ...n removed it must be replaced with a new lock nut 8 While holding the drive axle stationary pull the top of the knuckle out and down until it is free of the drive axle KC285 9 Place a drain pan under the ATV to contain any oil leakage then using a slide hammer remove the drive axle KC286 REMOVING FRONT DRIVE AXLE NOTE For removing a front drive axle see Front Differential in this section CLEANING ...

Page 100: ...ess of the bearing must face toward the housing CD022 5 Inspect the splines of the shaft the bearing ring and the housing for damage NOTE If any damage is apparent to the splines the bearing ring and or the housing the drive axle must be replaced as an assembly 6 Using a side cutters or suitable substitute remove the small clamp from the shaft CD752 NOTE At this point if the outside boot is damage...

Page 101: ...ot Clamp Tool secure both outside boot clamps CD024 ASSEMBLING AXLES 1 Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly NOTE The boot is positioned correctly when the small end of the boot seats down into the recessed groove CD754 2 Using the boot clamp pliers secure the small clamp of the inner boot ATV 1048 3 Apply 80 grams 2 3 of contents of...

Page 102: ...xle followed by a hex nut Tighten the hex nut finger tight at this time 4 If the brake caliper was removed position it on the knuckle and secure with existing cap screws Tighten the brake caliper cap screws to 20 ft lb 5 Pump up the hand brake lever then engage the brake lever lock 6 Tighten the hub hex nut from step 3 to 200 ft lb then install and spread a new cotter pin making sure each side of ...

Page 103: ...the left side of the frame then secure it to the frame with cap screws and lock nuts Tighten to 38 ft lb 2 Secure the engine output flange to the rear gear case input flange with four cap screws and lock nuts Tighten to 20 ft lb 3 Install the rear drive axles see Drive Axles in this section Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the cot...

Page 104: ...ad a new cotter pin making sure each side of the pin is flush to the hub nut KC305 7 Install the wheel and tighten to 40 ft lb 8 Remove the ATV from the support stand Hydraulic Brake Caliper REMOVING DISASSEMBLING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Drain the brake fluid from the caliper hose and mas ter cylinder through the bleed screw by pumping the b...

Page 105: ... of the housing with a shop towel then keeping fingers clear of piston travel apply compressed air to the fluid port to blow the piston free of the housing Account for two seal rings in the housing PR713A PR715 7 Using an appropriate seal removal tool carefully remove the seals from the brake caliper housing then remove four O rings from the brake caliper housing noting the location of the differe...

Page 106: ...C 4 Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented NOTE It is very important to apply silicone grease to the O rings and caliper bores prior to assembly PR239C 5 Making sure brake fluid does not contact the brake pads compress the caliper holder toward the caliper and install the inner brake pad then install the outer pad CAUTION Make sure the...

Page 107: ...esulting in greatly increased stopping distance or loss of control leading to injury or death Problem Power not transmitted from engine to wheels Condition Remedy 1 Rear axle shafts serration worn broken 1 Replace shaft Problem Power not transmitted from engine to either front wheel Condition Remedy 1 Secondary drive driven gear teeth broken 2 Propeller shaft serration worn broken 3 Coupling damag...

Page 108: ...rrect or repair leaks 5 Replace master cylinder Problem Brake lever travel excessive Condition Remedy 1 Hydraulic system entrapped air 2 Brake fluid low 3 Brake fluid incorrect 4 Piston seal cup worn 1 Bleed hydraulic system 2 Add fluid to proper level 3 Drain system replace with correct fluid 4 Replace master cylinder Problem Brake fluid leaking Condition Remedy 1 Connection joints loose 2 Hose c...

Page 109: ...st be replaced INSTALLING 1 Place bushings and sleeves where appropriate into shock eyelet then install shock with cap screws and nuts Tighten all nuts to 35 ft lb 2 Remove the ATV from the support stand Front A Arms REMOVING 1 Secure the ATV on a support stand to elevate the front wheels then remove the wheels 2 Remove the cotter pin from the nut Discard the cot ter pin 3 Remove the nut securing ...

Page 110: ...5 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 pin and spread the pin to secure the ...

Page 111: ...p 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 35 ft lb 11 Secure the boot guard to the lower A arm with the two cap screws Tighten securely 12 Install the wheel and tighten to 40 ft lb 13 Remove the ATV from the support stand Wheels and Tires 0742 948 TIRE SIZE The ATV is equipped with low pressure tubeless...

Page 112: ...only check and adjust the brakes as necessary and recheck operation see Periodic Maintenance 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 damage exists Problem Suspension too soft Condition Remedy 1 Spri...

Page 113: ... steering post cover then remove the cap screws securing the handlebar caps and move the handlebar out of the way Account for the two han dlebar caps KC0058 3 Remove the cap screws securing the upper steering post to the frame Account for the housing cap outer housing and inner housing KC307A 4 Remove the cotter pins from the inner tie rod ends then remove the nuts and disconnect the inner tie rod...

Page 114: ...t washer and cap screw Tighten to 40 ft lb KC184B 2 Apply grease to the inner and outer housings of the upper steering post support then with the housing cap in place secure with the cap screws Tighten to 20 ft lb KC307A 3 Using red Loctite 271 on the threads install the tie rod ends into the lower steering post arm and tighten to 30 ft lb then install new cotter pins KC184A 4 Place the handlebar ...

Page 115: ...e hub then remove the cotter pin from the nut 3 Remove the nut securing the hub 4 Remove the brake caliper 5 Remove the hub assembly 6 Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then remove the knuckle 9 Remove the snap ring from the knuckle th...

Page 116: ... then using a crisscross pattern tighten to 40 ft lb 12 Remove the ATV from the support stand Measuring Adjusting Toe Out 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 le...

Page 117: ...ct all welds for cracking or 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 Bum...

Page 118: ...ove the cap screws A then remove the rein stallable rivets B and remove the tank cover KC219A KC220 4 Remove the shift knob then remove the shift mecha nism 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 a...

Page 119: ...e front body supports then install the left side and right side 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 M...

Page 120: ...rame and the cap screws securing the rear fenders to the footwells KC317A KC316 2 Disconnect the battery negative cable first and remove from the battery compartment then discon nect 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 wa...

Page 121: ...hten all fasten ers securely KC317A KC320A 2 Connect the light connectors and secure to the frame then install the battery starter relay and auxiliary brake Connect all wiring making sure to connect the positive cables first KC279 KC322 3 Secure the rear fenders to the footwells and tighten the nuts securely 4 Install the side panels and seat Seat REMOVING INSTALLING 1 To remove the seat lift up o...

Page 122: ...ace 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 replace frame 5 Replac...

Page 123: ...ke 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 banjo fitting and bolt for cracks and dete rioration 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 banj...

Page 124: ...o the handlebar and secure with the two machine screws ADJUSTING To adjust throttle cable free play see Periodic Mainte nance LCD Gauge REPLACING To replace the LCD gauge use the following procedure 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...