Arctic Cat 2014 400, Service Manual

Page 1: ...400 ATV SERVICE MANUAL 2014 ...

Page 2: ... decals display the words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of serious injury or even death A CAUTION identifies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibil...

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Page 4: ...ide Components 52 Servicing Left Side Components 54 Installing Left Side Components 56 Right Side Components 57 Removing Right Side Components 57 Servicing Right Side Components 60 Installing Right Side Components 61 Center Crankcase Components 64 Separating Crankcase Halves 64 Disassembling Crankcase Half 65 Servicing Center Crankcase Components 66 Assembling Crankcase Half 71 Joining Crankcase H...

Page 5: ...M CRANKSHAFT Connecting Rod small end max 20 021 mm Connecting Rod big end side to side max 0 7 mm Connecting Rod big end width 21 95 22 00 mm Connecting Rod small end deflection max 3 0 mm Crankshaft web to web 60 9 mm Crankshaft Runout max 0 03 mm CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 060 0 073 mm Piston Diameter 15 mm from Skirt End 80 98 81 00 mm Piston Ring Free End Gap ...

Page 6: ...e 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 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 En...

Page 7: ...anol or 5 methane are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system RECOMMENDED ENGINE TRANSMISSION OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil which has been specifically formulated for use in this Arctic Cat engine Although A...

Page 8: ...r rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds Stop the engine Install the air filter and housing cover NOTE At this point drain the carburetor float chamber 4 Plug the exhaust outlet on the muffler with a clean cloth 5 Apply light oil to the upper steering post bushing and plungers of the shock absorbers 6 Tighten all nuts bolts cap screws and screws M...

Page 9: ...t the battery cables 6 Check the entire brake systems fluid level pads etc all controls lights and headlight aim adjust or replace as necessary 7 Tighten all nuts bolts cap screws and screws mak ing sure all calibrated nuts cap screws and bolts are tightened to specifications 8 Check tire pressure Inflate to recommended pressure as necessary 9 Make sure the steering moves freely and does not bind ...

Page 10: ...uster 0444 178 Item Initial Service After Break In First Mo or 100 Mi Every Day EveryMonthor 100 Miles Every 3 Months or 300 Miles Every 6 Months or 500 Miles Every Year or 1500 Miles As Needed Battery I 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...

Page 11: ...n dip the ele ment 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 in...

Page 12: ...mission Ser vicing 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...

Page 13: ... 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 While holding the throttle lever in the full open posi tion crank the engine over with the elect...

Page 14: ...er then loosen and remove the arrester KC334A 2 Using a suitable brush clean the carbon deposits 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 ...

Page 15: ...e 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 Pour the specified amount of the re...

Page 16: ...h ATV0082A 737 651B 3 After all the oil has been drained install the drain plugs and tighten to 45 in lb 4 Pour the appropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole 5 Install the fill plugs and tighten to 16 ft lb NOTE If the differential rear drive oil is contami nated with water inspect the drain plug filler plug and or bladder Tires TIRE SIZES The ATV is equi...

Page 17: ...r coil bracket may be bent or damaged or the CDI unit may be faulty Lights Rotate the ignition switch to the lights position the head lights and taillights should illuminate Test the brake lights by compressing the brake lever The brakelights 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 ...

Page 18: ... 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 housing and turn clockwise to secure KC158B CHECKING ADJUSTING HEADLIGHT AIM The...

Page 19: ... the ATV functions but the shift lever does not corre spond with the gear indicated on the LCD adjust the shift linkage To adjust proceed to ADJUSTING ADJUSTING 1 Remove the seat then remove the left side engine cover 2 With the ignition switch in the ON position loosen jam nut A left hand threads then loosen jam nut C and with the shift lever in the reverse position adjust the coupler B until the...

Page 20: ...s firm E At this point perform step B C and D on the FRONT RIGHT bleeder screw then move to the FRONT LEFT bleeder screw and follow the same procedure 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...

Page 21: ...large enough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate to 0 5 mph 3 Repeat procedure on each 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...

Page 22: ...lley faces approximately 3 4 in KC137 5 Pinching the V belt together in front of the driven pulley pull it forward and outward off the clutch shaft then remove it from the driven pulley KC136 6 Inspect the faces of the drive and driven pulleys for scoring pitting cracks 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...

Page 23: ... KC141 4 Remove the cap screw from the fixed driven face then rotate the pulleys counterclockwise until the driven pulley faces are together 5 With the two alignment pins installed in the V belt housing and a new V belt cover gasket in place install the V belt cover Using the pattern shown secure with the cap screws tightened to 8 ft lb KC142A KC153A 6 Slide the auxiliary brake pedal fully onto th...

Page 24: ...tter pins not damaged or missing Front Body Panel Fender REMOVING 1 Remove the seat and both side panels 2 Remove the front rack then disconnect the head light running light connectors located on the frame KC224 NOTE Use a small screwdriver to disengage the tab connector allowing the connector assembly to be removed from the frame KC223 3 Remove the cap screws A then remove the rein stallable rive...

Page 25: ...rs and attach onto the frame KC210G KC224 3 Install the screws securing the front body to the 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 secur...

Page 26: ...rear body panel components with warm soap and water 2 Inspect side panels and rear body panel for cracks and loose rivets 3 Inspect threaded areas of all mounting bosses for stripping 4 Inspect for missing decals INSTALLING 1 Place the rear body panel fender in place on the ATV then secure with the cap screws on the side frame and the rear rack assembly Tighten all fasten ers securely KC317A KC320...

Page 27: ...e the outer tie rod ends from the knuckles at this time 5 Remove the cap screw securing the lower steering post to the bearing Account for a flat washer KC184B 6 Remove the steering post from the ATV CLEANING AND INSPECTING 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 for ...

Page 28: ...hreads 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 and caps in place on the steering post and with the handlebar correctly positioned tighten the cap screws to 20 ft lb KC0058 5 Install the steering post cover then install the front body panel fender LCD Gauge REPLACING 1 Remove the two screws securing ...

Page 29: ...from end to end and peel off the rubber 4 Using an adhesive solvent clean all glue residue from the handlebar INSTALLING 1 Apply a liberal amount of Handlebar Grip Adhesive to the inside of the new grip 2 Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up NOTE A quick firm push is required to seat the grip completely on the handlebar Install while...

Page 30: ...he two halves of the throttle control onto the handlebar and secure with the two machine screws ADJUSTING To adjust throttle cable free play see Periodic Mainte nance Adjusting Throttle Cable Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the wheel cap from the hub then remove the cotter pin from the nut 3 Remove...

Page 31: ...l the knuckle to the upper and lower ball joints and secure with the two cap screws Tighten to 35 ft lb KC313A 3 Install the tie rod end and secure with the nut Tighten to 30 ft lb then install a new cotter pin and spread the pin NOTE During assembling new cotter pins should be installed 4 Apply a small amount of grease to the hub splines 5 Install the hub assembly onto the splines of the shaft 6 ...

Page 32: ... NOTE Care must be taken not to allow the handle bar to turn while securing it NOTE The front wheels do not have to be removed to adjust the tie rod Also care should be taken not to disturb the handlebar position 6 Using a permanent marker of some type mark the center of each front tire at a height parallel to the belly panel AF789D 7 Measure the distance between the marks at a height parallel to ...

Page 33: ...n the lock nut from step 1 to 20 ft lb then tighten the cap screws securely Exhaust System REMOVING MUFFLER 1 Remove the two exhaust springs at the muf fler exhaust pipe juncture KC170 2 Slide the muffler rearward to clear the mounting lugs and remove the muffler Account for a grafoil seal INSPECTING MUFFLER 1 Inspect muffler externally for cracks holes and dents 2 Inspect the muffler internally b...

Page 34: ...e lug nuts wheel studs 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated 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 ...

Page 35: ...use of new gas kets lock nuts and seals and lubricating all internal components when servicing the engine transmis sion SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appro priate tool description NOTE Special tools are available from the Arctic Cat Service Department...

Page 36: ...een valve screen 4 Replace valve Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Valve clearance out of adjustment 5 Carburetor jets obstructed 1 Clean plug 2 Replace stator coil 3 Replace CDI unit 4 Adjust clearance 5 Clean jets Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excessive 2 Valve spring s we...

Page 37: ...4 Cam rocker arms tappets worn 5 Spark plug gap too narrow 6 Ignition coil defective 7 Float level too low 8 Air cleaner element obstructed 9 Fuel hose obstructed 1 Shift into higher gear decrease speed 2 Replace springs 3 Correct timing check chain sprockets and cam chain ten sioner 4 Replace cam arms tappets 5 Adjust gap 6 Replace ignition coil 7 Adjust float height 8 Clean element 9 Clean or re...

Page 38: ...defective 5 Oil circuit obstructed 6 Intake manifold leaking air 7 Fan malfunctioning 8 Fan switch malfunctioning 9 Gasoline level in float chamber too low 1 Clean piston 2 Add oil 3 Drain replace gasoline 4 Replace pump 5 Clean circuit 6 Tighten replace manifold 7 Check fan fuse replace fan 8 Replace fan switch 9 Adjust float height ...

Page 39: ...nd cooling fan connector KC251 KC250 KC249 4 Disconnect the speedometer sensor then remove the E clip securing the shift rod to the shift arm and discon nect 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 ...

Page 40: ...seal and seal 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 KC243 ...

Page 41: ...ate 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 valve inspection covers Remove the two covers Account for the O rings MD1264 NOTE Keep the mounting hardware with the covers for assembly purpo...

Page 42: ...sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cyl inder head Account for an alignment pin NOTE Loop the chain over the cylinder and secure it to keep it from falling into the crankcase MD1132 7 Remove the cam chain tensioner by lifting it from the chain cavity then remove the two lower nuts securing the cylinder head to the cylinder one in front a...

Page 43: ...nt pins MD1214 13 Using an awl remove the piston pin circlips Take care not to drop them into the crankcase MD1213 14 Using Piston Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston NOTE It is advisable to remove the opposite side circlip prior to using the puller MD1219 AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub se...

Page 44: ...il 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 springs and remove the valve keepers Account for an upper spring retainer CC994 2 Rem...

Page 45: ...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 Measuring Valve Guide Valve Stem Deflection Wobble Method 1 Mount a dial indicator and base on the surface plate then place the cylinder head on the surface plate 2 Install the valve into the cy...

Page 46: ...le install the ends of the springs with the closest wound coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor compress the valve springs and install the valve keepers CC994 PISTON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal...

Page 47: ... the piston pin outside diameter at each end and in the center If measurement exceeds specifica tions the piston pin must be replaced ATV 1070 2 Inspect and measure the connecting rod small end If the measurement exceeds specifications the con necting rod must be replaced see Center Crankcase Components in this section 3 Insert an inside dial indicator into the piston pin bore Take two measurement...

Page 48: ...amaged threads using a heli coil insert 3 Place the cylinder head on the surface plate covered with 400 grit wet or dry sandpaper Using light pressure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assem bly by continuing to move the cylinder head in a fi...

Page 49: ...ash the cylinder in parts cleaning solvent 3 Inspect the cylinder for pitting scoring scuffing and corrosion If marks are found repair the surface using a 320 grit ball hone NOTE To 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 us...

Page 50: ...ad and secure with the cap screws Tighten securely NOTE Do not rotate the camshaft when measuring clearance 4 Remove the cap screws securing the cylinder head cover to the cylinder then remove the cylinder head cover and camshaft MD1261 5 Match the width of the plasti gauge with the chart found on the plasti gauge packaging to determine camshaft to cylinder head and cylinder head cover clearance C...

Page 51: ...new cylinder gasket into position then place a piston holder 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 hol...

Page 52: ...g sure the cam chain is routed through the chain cavity MD1347 MD1163 7 Install the four cylinder head cap screws with wash ers 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 Tighten only until snug MD1270 8 Install the two lower nuts securing the cylinder head to the cylinder one in front ...

Page 53: ...installed in the camshaft loosely place the cam sprocket with the recessed side facing the camshaft lobes onto the camshaft and place it into position with the cam chain over the sprocket MD1359 14 Place the C ring into position in its groove in the cyl inder head MD1131 NOTE At this point oil the camshaft bearings cam lobes and the three seating journals on the cylinder head NOTE Note the positio...

Page 54: ...e tab to secure the cap screw 20 Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down wards 21 Remove the cap screw from the end of the chain ten sioner Account for the plunger spring and gasket MD1248 22 Depress the spring loaded lock and push the plunger into the tensioner MD1146 23 Place the cam chain tensioner assembly and gasket into the cylinde...

Page 55: ... then install and tighten the cap screws to 8 ft lb MD1264 31 Install the spark plug and tighten securely then install the timing inspection plug Left Side Components 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 NOTE The engine transmission...

Page 56: ...ctive 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 Remover break the rotor fly wheel assembly loose from the crankshaft Remove the remover the crankshaft prote...

Page 57: ... replaced as an assembly 13 Using an impact screwdriver remove the three Phil lips head screws holding the crankshaft bearing retainer Remove the crankshaft bearing retainer MD1122 Servicing Left Side Components INSPECTING STARTER CLUTCH GEAR 1 Place the starter clutch gear onto the rotor flywheel and attempt to rotate the starter clutch gear clock wise It should lock up to the rotor flywheel Rota...

Page 58: ...h the cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a crisscross pattern Make sure the one way bearing is installed with the notches directed away from the rotor flywheel FI576A FI578 REPLACING STARTER GEAR BEARING 1 Support the starter clutch gear in a press making sure to support the hub around the entire circumference then using a suitable bearing ...

Page 59: ...s MD1239 6 Install starter idler gear No 2 and starter idler gear No 1 MD1305 7 Place the key into its notch then slide the rotor fly wheel with the ring gear in place over the crank shaft 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 ...

Page 60: ...A 2 Remove the cap screws securing the V belt cover to the clutch cover then slide the brake pedal outward and remove the V belt cover Account for two align ment pins 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 crankshaft MD1033 4 Remove the movable drive face and spacer Account for t...

Page 61: ...t 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 side crankcase half Account for two alignment pins and gasket MD1115 D Centrifugal Clutch Assembly E Oil Pump Drive Gear F Oil Pump Driven Gear G Oil Pump NOTE Steps 1 10 in the preceding sub section must precede th...

Page 62: ...ing purposes MD1286 12 Remove the left hand threaded nut holding the cen trifugal clutch assembly MD1014 MD1016 13 Remove the cam chain MD1335 14 Remove the oil pump drive gear cap screw MD1018 15 Remove oil pump drive gear Account for the pin CAUTION Care must be taken when removing the nut it has left hand threads ...

Page 63: ...en wear chips cracks or discoloration 2 Inspect the depth of the grooves in the clutch shoes If any shoe is worn to the bottom of the groove replace the complete set ATV1014 INSPECTING CENTRIFUGAL CLUTCH HOUSING 1 Inspect the clutch housing for burns marks scuffs cracks scratches or uneven wear 2 If the housing is damaged in any way the housing must be replaced AT THIS POINT To service clutch comp...

Page 64: ...le to remove the screw securing the pump halves If the oil pump is damaged it must be replaced NOTE The oil pump is a non serviceable compo nent and must be replaced as a complete assembly DRIVEN PULLEY ASSEMBLY NOTE The driven pulley assembly is a non service able component and must be replaced as a complete assembly Installing Right Side Components A Oil Pump 1 Place two alignment pins and the o...

Page 65: ...nge nut should be directed towards the clutch shoe 6 Install the one way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase MD1286 KC325A KC326B B Clutch Cover C Fixed Drive Face D Movable Drive Face NOTE Steps 1 6 in the preceding sub section must precede this procedure 7 Install two alignment pins and place the clutch cover gasket into position Install ...

Page 66: ...t lb MD1068 KC134 11 Slide the fixed drive face assembly onto the front shaft 12 Spread the faces of the driven pulley by threading a V 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 13 Making sure the mo...

Page 67: ...2A Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Complete Remov ing procedures for Top Side Left Side and Right Side must precede 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 ...

Page 68: ...ring on the bearing boss next to the driven gear MD1317 NOTE Note the location of the bearing alignment pin on the secondary output shaft 2 Remove 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 clus...

Page 69: ...ven 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 acceptable range no cor...

Page 70: ...ed and the above Tooth Contact Shim Correction chart must be consulted CRANKSHAFT ASSEMBLY Measuring Connecting Rod Small End Inside Diameter NOTE The crankshaft and connecting rod is a non serviceable assembly If any component is out of specification the assembly must be replaced 1 Insert a snap gauge into the upper connecting rod small end bore then remove the gauge and measure it with micromete...

Page 71: ...unout must not exceed specifications NOTE Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the out side edge of one web to the outside edge of the other web KC513 2 Acceptable width range must be within specifica tions COUNTERSHAFT Disassemb...

Page 72: ...e low driven gear along with the bearing and bushing FI666 FI667 4 Remove the splined washer then remove the circlip securing the high low sliding dog Remove the slid ing dog FI668 FI669 5 Remove the circlip securing the high driven gear then remove a washer the high driven gear along with the bearing and bushing and remove the high driven washer FI670 FI671 ...

Page 73: ...on the countershaft and secure with snap ring 7 then install the splined washer 8 FI668A 3 Install the low driven bushing 10 bearing 9 and gear 11 on the countershaft then install splined washer 12 FI667A FI666 4 Place the reverse driven bushing 13 onto the shaft then install the bearing 14 gear 15 and splined washer 16 Secure with a snap ring FI665A FI664 5 Install the reverse dog on the shaft th...

Page 74: ...e 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 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...

Page 75: ... into position on the assembled countershaft and install into the crankcase as an assembly FI662 FI653 8 Align the shift forks to allow engagement with the shift cam then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase FI653A FI655A 9 Install the input driveshaft FI646 10 Install the spacer 1 shaft 2 reverse idler gear and washer 3 FI641A ...

Page 76: ...aces Place the right side half onto the left side half MD1336 2 Using a plastic mallet lightly tap the case halves together until cap screws can be installed 3 From the right side install the crankcase cap screws noting the location of the different sized cap screws then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap s...

Page 77: ...me member KC216 2 Install the front and rear engine mounting through bolts and secure with the flange nuts Tighten to 38 ft lb 3 Align the front and rear output flanges with the drive couplers then secure with the screws and tighten to 20 ft lb KC242 KC243 4 Install the front and rear V belt cooling boots and secure with the existing hardware KC235 KC236 5 Connect the stator coil trigger coil and ...

Page 78: ...e 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 KC245A 8 Install the air filter housing onto the frame then con nect the inlet air duct air silencer duct and intake housing to carburetor boot and tighten all hose clamps securely KC254 9 Install the shift rod onto the shift arm with bushing and flat wash...

Page 79: ... pedal and secure with a flat washer and cap screw Tighten to 20 ft lb KC232A KC149A 12 Install the heat shield then install the gas tank see Fuel Lubrication Cooling Gas Tank 13 Install the front body panel front rack and foot wells 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 ...

Page 80: ...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 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 ...

Page 81: ... The carburetor 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 Fl...

Page 82: ...three screws 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...

Page 83: ...t 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 or damage NOTE If the slow jet is ob...

Page 84: ...all the main 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...

Page 85: ...eedle 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 connect the electronic choke connector and install the throttle cable onto the throttle arm CAUTION It is important to press down on...

Page 86: ...sure the alignment 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 ...

Page 87: ...remove gas tank cover and place the tank cap back on the tank KC220 5 Using suitable straps hook the body panel at the rear of the gas tank and route it over the handlebar to the front rack then pull it tight to spread open the panel at the rear of the gas tank KC509A 6 Remove the fuel shut off valve knob KC515A 7 Remove the cap screw A securing the gas tank to the frame then unplug the fuel level...

Page 88: ...e making sure the heat shield is in position KC252A 2 Using a suitable block support the rear of the tank and connect the gasline hose Secure with the clamp KC241A 3 Remove the block and slide the tank forward con nect the fuel level sensor wires and insert the cap screw into the rear of tank Tighten securely KC514 4 Remove the straps then using the existing cap screws install the instrument pod T...

Page 89: ... in diagnostic mode and select tACH 2 Connect the Oil Pressure Test Kit to the oil filter drain plug KC195A KC267 NOTE Some oil seepage may occur when installing the oil pressure gauge Wipe up oil residue with a cloth 3 Warm up the engine to normal operating temperature cooling fan cycling then increase engine RPM to 3000 RPM The oil pressure must read 1 1 1 7 kg cm2 16 25 psi KC268 NOTE If the oi...

Page 90: ...etor leaking air 4 Gas contaminated 1 Clean jet 2 Clean passage 3 Replace gasket 4 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 Slow jet obstructed loose 2 Slow jet outlet obstructed 3 Low speed fuel screw setting incorrect 4 Float height incorrect 1 Clean tighten jet 2 Clean outlet 3 Adjust screw 4 Adjust float height Problem Medium or high speed ...

Page 91: ...ging NOTE Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain 800E 1 When charging a battery in the vehicle be sure the ignition switch is in the OFF position 2 Clean the battery terminals with a solution of baking soda and...

Page 92: ...after charging the battery does not per form to operator expectations bring the battery to an authorized Arctic Cat dealer for further troubleshoot ing RPM Limiter NOTE The ATV is equipped with a CDI unit that retards ignition timing when maximum RPM is approached When the RPM limiter is activated it could be misinterpreted as a high speed misfire Testing Electrical Components All of the electrica...

Page 93: ... 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 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 ...

Page 94: ... remove a fuse 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 T...

Page 95: ...ignition coil Spark 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 or Fluke Model 77 Multimeter ...

Page 96: ...sing 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 KC339D VOLTAGE NOTE Perform this test on the main harness con nector...

Page 97: ...eter selector to the OHMS position 2 Connect one tester lead to one lavender red wire then connect the other tester wire to the green red wire The meter must show less than 1 ohm 3 Depress and hold the reverse override button The meter must show an open circuit NOTE If the meter does not show as specified replace the switch Gear Position Switch The gear position switch connector is located on the ...

Page 98: ...ing must be within specification Starter Relay 1 Remove the seat then using the multimeter set to the DC Voltage position check the relay as follows 2 Connect the red tester lead to the positive battery ter minal then connect the black tester lead to the starter cable connection on the starter relay The meter must show battery voltage NOTE Make sure that the ignition switch is in the ON position t...

Page 99: ...ive it is advisable to perform a CDI peak voltage test see Ignition Coil in this section and or perform a continuity test of the wiring harness from the CDI connector to the CDI unit Regulator Rectifier The regulator rectifier is located under the front rack and front fenders above the oil cooler TESTING 1 Start engine and warm up to normal operating tem peratures then connect a multimeter to the ...

Page 100: ...ng harness TAILLIGHTS BRAKELIGHTS Voltage Taillights NOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the LIGHTS position 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire then connect the red tester lead to the brown blue wire 3 The meter must show battery voltage NOTE If the meter does not s...

Page 101: ...t 5 Replace stator coil Problem Spark plug fouled with carbon Condition Remedy 1 Gasoline incorrect 2 Air cleaner element dirty 3 Spark plug incorrect too cold 4 Valve seals cracked missing 5 Oil rings worn broken 6 Mixture too rich 7 Idling RPM too high 1 Change to correct gasoline 2 Clean element 3 Replace plug 4 Replace seals 5 Replace rings 6 Replace jets with correct size 7 Adjust carburetor ...

Page 102: ...y 5 Turn on switches 6 Connect tighten repair connections Problem Battery sulfation Acidic white powdery substance or spots on surfaces of cell plates Condition Remedy 1 Charging rate too low too high 2 Battery run down damaged 3 Electrolyte contaminated 4 Battery electrolyte insufficient 5 Specific gravity too low 1 Repair charging system 2 Replace battery 3 Replace battery 4 Keep electrolyte to ...

Page 103: ...ake lever lock 7 Remove the upper and lower ball joint cap screws taking care not to strip the threads AF628D 8 Pull the steering knuckle away from the axle taking care not to damage the seals as the axle clears the knuckle KC314 9 Support the axle to not allow it to drop or hang 10 Pull out on the axle until completely extended then push it back in approximately one half inch and pull out sharply...

Page 104: ...tion and sound judgment 1 Remove the cap screws securing the front drive actu ator and remove the actuator CD102 2 Remove the cap screws securing the pinion housing then using a rubber mallet remove the housing Account for a gasket Note the location of all the components for assembling purposes 3 Using a side cutter remove the boot clamps then remove the boots and splined drive from the input shaf...

Page 105: ...l making sure it is flush with the edge of the housing 3 Lubricate the input shaft splines with High Perfor mance 2 Molybdenum Disulphide Grease NOTE Any time drive splines are separated clean all splines with parts cleaning solvent and dry with compressed air then lubricate with recommended grease KX221 KX222 4 Install the input shaft into the housing then install the front boot and secure with a...

Page 106: ...bling purposes KX173 3 Using a plastic mallet tap lightly to remove the dif ferential cover Account for an O ring and a shim NOTE If the cover is difficult to remove pry on the cover in more than one recessed location GC063 4 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 5 Unstake the lock collar t...

Page 107: ...se tolerances therefore it is very impor tant to properly adjust any gear set prior to final assem bly The following procedure can be used on both front differ ential or rear drive gear case NOTE All bearings must be installed in the gear case and the pinion properly installed before pro ceeding Backlash NOTE Always set backlash prior to any other shim ming 1 Install the existing shim or a 0 051 0...

Page 108: ...uge at a 90 angle and on the index mark GC070 GC072A 6 Zero the dial indicator then while holding the pinion stationary rock the ring gear assembly forward and back and record the backlash Backlash must be 0 011 0 015 in If backlash is within specifications proceed to Ring Gear End Play If backlash is not within specifications increase shim thickness to increase backlash or decrease shim thickness...

Page 109: ... the thrust button with shim into the gear case cover and tighten securely left hand threads GC057A 2 Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge Clearance should be 0 002 0 004 in GC058A 3 If clearance is as specified remove the ring gear and thrust button then place a drop of red Loctite 271 on the threads and ...

Page 110: ...hten to 18 ft lb CD110 Removing Needle Bearing NOTE Removing the needle bearing is rarely nec essary Avoid removing the needle bearing unless the bearing is clearly damaged NOTE This procedure can 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 ...

Page 111: ... to 125 ft lb 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 CC...

Page 112: ...install the cap screws and nuts Tighten to 38 ft lb KC488 2 Install the cap screws securing the flange couplers together and tighten to 20 ft lb AG925 3 Install the front axles AF610D AF897D 4 Install the wheels and tighten to 40 ft lb steel or 80 ft lb aluminum 5 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid gear lubricant into the differential and install the filler plug Tighten to 16 ft lb 6 Remov...

Page 113: ...ve axle into place in the gear case NOTE To assure proper seating of the axle give it a light pull the axle should remain clipped in place 2 Swing the knuckle up and onto the drive axle then place the knuckle into place in the upper A arm Secure the knuckle to the A arm with a cap screw and a new lock nut Tighten to 35 ft lb 3 Place the hub into position on the axle followed by a hex nuts Tighten ...

Page 114: ...into position through 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 Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the cotter pin fr...

Page 115: ...as an assembly REMOVING 1 Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con tainer Remove the reservoir cover then open the bleeder valve Allow the brake fluid to drain com pletely NOTE Compressing the brake lever several times will quicken the draining process AF637D 2 Place an absorbent towel around the connection to absorb brake fluid Remo...

Page 116: ...ad 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 dis card the O ring PR239B NOTE The O ring is used for shipping purposes and provides no function in operation 6 Cover the piston end of the housing with a shop towel then keeping fingers clear of piston trave...

Page 117: ...spect the piston surface for scoring discoloration 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 brake fluid to the cylinder bore of the housing seals and brake piston PR715 PR717A 2 Press the piston into the caliper housing using hand pressure only Comp...

Page 118: ...se fitting and install it on the caliper Tighten to 20 ft lb 8 Fill the reservoir then bleed the brake system see Periodic Maintenance Hydraulic Brake Systems 9 Install the wheel Tighten to 40 ft lb steel or 80 ft lb aluminum 10 Remove the ATV from the support stand and verify brake operation CAUTION If brake pads become contaminated with brake fluid they must be thoroughly cleaned with brake clea...

Page 119: ... coupling 4 Replace joint 5 Replace gear s 6 Replace gears pinions 7 Replace 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...

Page 120: ...r assembly must 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 ...

Page 121: ...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 nut 11 Install the wheel and tighten to 40 ft lb steel or 80 ft lb aluminum 12 Remove the ATV fr...

Page 122: ... 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 steel or 80 ft lb aluminum 13 Remove the ATV from the support stand Wheels and Tires TIRE SIZE The ATV is equipped with low pressure tubeless tires of the size and type listed in the General Information sec tion Do not under any circumstances su...

Page 123: ...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 Spring s weak 2 Shock absorber damaged 3 Shock absorber preload too low 1 Replace spring s 2 Repl...

Page 124: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 829 ...