Arctic Cat 700 Diesel ATV 2007, Service Manual

Page 1: ...ze 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 The symbol CAUTION identifies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE i...

Page 2: ...on 2 Periodic Maintenance Tune Up 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 10 Aids for Maintenance 1 2 3 4 5 6 7 8 9 10 2007 700 Diesel 700 Diesel ATV Service Manual ATV Service Manual 2007 ...

Page 3: ...SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS General Specifications 1 2 Break In Procedure 1 2 Fuel Oil Lubricant 1 3 Genuine Parts 1 4 Preparation For Storage 1 4 Preparation After Storage 1 4 Back to TOC ...

Page 4: ...er break in should include checking of all pre scribed adjustments and tightening of all fasteners FUEL INJECTION Type Lombardini Unit Injectors Idle RPM engine warm 800 900 Throttle Cable Free Play at lever 3 6 mm 1 8 1 4 in ELECTRICAL Glow Plug Type Lombardini Alternator Denso 12V 40 Amp CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxiliary Brake Tire Size Front 25 x 8 12 Rear 25 x 10 12...

Page 5: ... Lube or an equivalent gear lube which is SAE approved 80W 90 hypoid This lubricant meets all of the lubrica tion requirements of the Arctic Cat ATV front differen tials and rear drives FILLING FUEL TANK ATV0049B Since fuel expands as its temperature rises the fuel tank must be filled to its rated capacity only Expan sion room must be maintained in the tank particularly if the tank is filled with ...

Page 6: ...ean the battery posts and cables and store in a clean dry area 9 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 proce dure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the muf fler 3 Check...

Page 7: ...ission Lubricant 2 7 Front Differential Rear Drive Lubricant 2 8 Tires 2 8 Steering Components 2 9 Driveshaft Coupling 2 9 Suspension Shock Absorbers Bushings 2 9 Nuts Cap Screws Screws Bolts 2 9 Injector Timing 2 9 Headlight Taillight Brakelight 2 9 Switches 2 10 Shift Lever 2 11 Frame Welds Racks 2 11 Electrical Connections 2 11 Hydraulic Brake Systems 2 11 Burnishing Brake Pads 2 13 Coolant 2 1...

Page 8: ...Engine Oil Filter Replace after initial 300 miles R R Front Differential Rear Drive Lubricant I R 4 Yrs Transmission Lubricant I I R 4 Yrs Tires Air Pressure I R Steering Components I I R V Belt I l R Suspension Ball joint boots drive axle boots front and rear tie rods differential and rear drive bellows I l R Nuts Cap Screws Screws Bolts I I A Injector Timing I A Headlight Taillight Brakelight I ...

Page 9: ... secure with the hold down bracket 5 Connect cables to the proper terminals positive cable to the positive terminal and negative cable to the negative terminal Connect the neg ative cable last Fuses The fuses are located in a power distribution module PDM under the seat If there is any type of electrical system failure always check the fuses first NOTE To remove a fuse compress the locking tabs on...

Page 10: ...cotton fabric safety element at this time DE007 3 Clean dust and debris from the air filter housing then remove the cotton fabric safety element using care not to allow dirt and debris to enter the engine DE008 4 Lightly tap the dry paper air filter to dislodge the dirt and dust Do not use compressed air 5 Insert a suitable light into the dry paper air filter and look for any pin points of light s...

Page 11: ...ntenance Chart clean the spark arrester using the following procedure 1 Remove the three cap screws securing the spark arrester assembly to the muffler then loosen and remove the arrester CF105A 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 a...

Page 12: ...and com pletely 1 Park the ATV on level ground 2 Remove the engine oil filler cap DE025A 3 Remove the drain plug from the bottom of the engine and drain the oil into a drain pan DE017A 4 Remove the right side engine cover 5 Using the adjustable Oil Filter Wrench p n 0644 389 and a suitable wrench remove the old oil filter NOTE Clean up any excess oil after removing the filter 6 Apply oil to a new ...

Page 13: ... accord ing to the Maintenance Schedule When adding or changing the lubricant use approved SAE 80W 90 hypoid and use the following procedure 1 Place the ATV on level ground 2 Remove the transmission fill plug Make sure not to allow contaminants to enter the opening DE026A 3 Remove the transmission drain plug from the bot tom of the transmission and drain the lubricant into a drain pan DE016A 4 Ins...

Page 14: ... plugs and tighten to specifications see Sec tion 10 5 Pour the appropriate amount of recommended lubricant into each filler hole 6 Install the filler plugs NOTE If the differential rear drive lubricant is contaminated with water inspect the drain plug and filler plug Tires TIRE SIZES The ATV is equipped with low pressure tubeless tires of the size and type listed see Section 1 Do not under any ci...

Page 15: ...ews Bolts Tighten all nuts cap screws screws and bolts Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws screws and bolts are tight ened to specifications see Section 10 Injector Timing To check adjust injector timing see Top Side Compo nents in Section 3 Headlight Taillight Brakelight Each time the ATV is used li...

Page 16: ... of each headlight 3 Using the measurements obtained in step 2 make horizontal marks on the aiming surface 4 Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights 5 Switch on the lights Make sure the HIGH beam is on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when the most intense beam is centered on the ver tical...

Page 17: ...H High L Low and R Reverse NOTE An E Error in the gear position icon indi cates no signal or a poor ground wire connection in the circuit Troubleshoot the harness connec tors gear shift position connector gear shift posi tion switch and LCD connector 7 Install the seat and left side engine cover Frame Welds Racks The frame welds and racks should be checked period ically for damage bends cracks det...

Page 18: ...luid in the reservoir will result in air in the system D Repeat step C until the brake lever is firm E At this point perform step B C and D on the other FRONT bleeder screw then move to the REAR bleeder screw and follow the same pro cedure 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 leak...

Page 19: ...auxiliary brake if necessary 5 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed Coolant The cooling system should be inspected daily for leak age and damage Also the coolant level should be checked periodically When filling the cooling system use a coolant water mixture which will satisfy the coldest anticipated weather conditions of the area...

Page 20: ... the filler cap DE582A Checking Replacing V Belt REMOVING 1 Remove the right side footrest see Section 8 2 Remove the cap screws securing the V belt cover then using a rubber mallet gently tap on the cover tabs to loosen the cover Remove the cover 3 Remove the cap screw securing the drive clutch to the flywheel stub axle then remove the nut and lock washer securing the movable drive face to the fi...

Page 21: ... rearward 2 Using a block of wood and a mallet drive the V belt down between the sheaves of the driven pulley approximately one inch then squeeze the belt together and slide over the fixed drive hub and onto the one way clutch DE097A DE098A 3 Pinch the V belt together near its center and slide the movable drive face onto the drive hub Secure the drive face with a nut Tighten the nut to speci ficat...

Page 22: ...tuator should operate engaging four wheel drive NOTE It may be necessary to turn the handlebar or rock the ATV forward and backward to align the differential lock splines and allow engagement 3 Return the differential lock selector to the UNLOCK position and listen for the front drive actuator to operate 4 Turn the ignition switch to the OFF position Tighten the jam nut securely then install the b...

Page 23: ... until the lever becomes firm and resistance is observed The system will bleed itself through the tank return circuit 4 Check for any fuel leaks then start the engine and check for normal engine operation Back to TOC Back to Section TOC Back ...

Page 24: ...3 1 3 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 700 Diesel Table of Contents 3 2 Troubleshooting 3 78 Back to TOC ...

Page 25: ... 4 mm 1 35 in 30 2 mm 1 19 in Valve Clearance intake exhaust cold engine 0 20 mm 0 008 in Valve Guide Stem Clearance 0 015 0 060 mm 0 0006 0 0024 in Valve Guide Inside Diameter 7 005 7 020 mm 0 2758 0 2764 in Valve Stem Diameter 6 960 6 990 mm 0 2740 0 2752 in Valve Face intake exhaust Seat Width 1 6 2 0 mm 0 063 0 079 in Valve Spring Free Length min 43 0 mm 1 69 in CAMSHAFT AND CYLINDER HEAD Cams...

Page 26: ...71A 6 Loosen the two hose clamps securing the air diverter to the inlet hoses then remove the air diverter 7 Remove the upper radiator hose from the filler neck then loosen the hose clamp securing the filler neck to the thermostat housing and remove the filler neck DE073A NOTE Filler neck can remain attached to the overflow recovery hose 8 Remove the upper radiator hose from the radiator 9 Remove ...

Page 27: ...ove the fuel supply and fuel return hoses from the fuel rail DE065A 13 Disconnect the wire connectors from the tempera ture sensor oil pressure sensor gear shift position switch connector and voltage regulator then dis connect the starter solenoid glow plug power wire and the alternator positive wire DE104A DE067A CAUTION The fuel rail connections are easily bent Use care when removing the hose cl...

Page 28: ... exhaust pipe to the exhaust manifold then remove the exhaust pipe Account for a steel gasket 18 Place a suitable block between the oil pan and frame member then remove the front engine mount cap screw and nut Account for a flat washer DE089A DE086A 19 Remove the cap screw and nut from the upper right engine mount Account for a flat washer DE088A 20 Remove the nuts and cap screws from the left rea...

Page 29: ...ion can be removed for ser vicing without removing the engine To remove the transmission use the following procedure 1 Remove the front rack inner front splash shields foot pegs and forward footwells then remove the front body panel see Section 8 2 Remove three cap screws securing the front pro peller shaft to the front differential input coupler 3 Remove four cap screws securing the rear propel l...

Page 30: ...y 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 SPEED GOVERNOR Removing Disassembling 1 Remove the timing belt see Left Side Compo nents in this section 2 Remove the air filter assembly then remove the valve cover DE074 3 Disconnect the throttle cable then remove the cap screws sec...

Page 31: ...pulley DE276 7 Remove the front camshaft support housing then remove the governor flyweight assembly Account for a small O ring DE245A DE277 8 Remove the control spool thrust bearing and thrust washer Note the order of disassembly and keep together and in order for assembling purposes DE278A CAUTION Failure to rotate the engine away from TDC will leave the flywheel side piston in close proximity t...

Page 32: ...n control rack by remov ing screws A and B and spring C then remove the governor fork pivot pin Account for an O ring NOTE Do not loosen or remove screws D or E or fuel delivery equalization will have to be per formed DE291A DE327 CAUTION Do not break the seal or turn the torque limiter adjuster screw Severe engine damage could occur Back to TOC Back to Section TOC Next Back ...

Page 33: ...eight assembly for loose pins worn contact points or excessive pivot point wear DE247A 2 Inspect all springs links and pivot pins for proper tension excessive wear or loose fit DE254A DE256A 3 Inspect the control spool thrust bearing and thrust washer for scoring excessive wear or missing bearing rollers DE278A Back to TOC Back to Section TOC Next Back ...

Page 34: ...h low speed spring assembly to the throttle control arm then place the manifold and gasket into position and secure with the seven cap screws Tighten securely DE258A DE248A 4 Install the fuel injection control rack making sure the slotted end engages the governor linkage sleeve then tighten the cap screws to specifica tions DE534A 5 Connect the throttle linkage into the throttle con trol lever the...

Page 35: ...6 8 Being careful not to damage the oil seal lightly coat the camshaft drive pulley flange with clean engine oil and install on the camshaft NOTE The camshaft drive pulley has a molded extrusion in the pulley bore that must engage the keyway in the camshaft DE574A 9 Secure the camshaft drive pulley to the camshaft with a washer and cap screw then using an appro priate holding tool tighten the cap ...

Page 36: ... then remove the air filter assembly and mount ing bracket and air diverter with ducts DE074A DE516A 3 Use duct tape to cover the engine air intake boot to prevent dirt or debris from entering the engine 4 Disconnect the oil pressure switch connector from the switch located on the right side of the valve cover then remove the fuel lift pump see Lift Pump in Section 4 DE077B 5 Disconnect the crankc...

Page 37: ...event valve damage when turning the camshaft then rotate the camshaft until one of the unit injector push rods is fully extended into the injector pump barrel DE275A DE404A 9 Place a holding pin into the injector pump barrel then rotate the camshaft until the second injector is fully compressed and install a holding pin DE328A 10 Remove the three nuts securing the rocker arm assembly to the cylind...

Page 38: ...embly Account for an O ring DE245A DE246A 13 Remove the governor control spool thrust bear ing and thrust washer keeping all components in order of disassembly DE278A 14 Remove the camshaft end cover then gently slide the camshaft toward the flywheel end of the engine Rotate the camshaft slightly to prevent binding and hanging in the camshaft bores Account for the fuel pump eccentric bushing DE297...

Page 39: ... lift pump eccentric and bushing for excessive wear scoring or pitting DE524 5 Inspect rocker arms camshaft followers and rocker shaft for excessive wear broken or scored rollers or cracked rocker arm shaft supports DE546A DE547A DE528A CAUTION Make sure to support the camshaft while the jour nals are pulled clear of the journal bores or damage to journal bores may occur WARNING Always wear safety...

Page 40: ...41 NOTE If the rocker arm assembly is to be disas sembled label all rocker arms for installing pur poses If the rocker arms are mixed up the complete overhead must be adjusted 9 After labeling rocker arms and supports remove components from the rocker arm shaft 10 Inspect the wear points on the rocker arm shaft and using a micrometer measure the shaft The mea surements must be within specification...

Page 41: ...ions 1 Coat the camshaft journals lobes and camshaft bores in the cylinder head with clean engine oil then carefully insert the camshaft into the cylinder head being careful not to nick or jam journals or journal bores DE525 2 Install the lift pump eccentric bushing onto the camshaft then install the camshaft end cover using a new O ring Tighten the cap screws securely DE540A DE297A 3 Insert the l...

Page 42: ...mbly and install on the camshaft then hold the fly weight assembly and remove the rubber band Install a new O ring on the camshaft DE535 DE536 DE537 6 Using a new O ring install the camshaft support housing and tighten the cap screws to specifica tions DE245A 7 Install the camshaft drive pulley and cap screw then using a suitable holding tool tighten the cap screw to specifications DE262 Back to T...

Page 43: ...il seal then carefully install the valve cover with a new gasket and oil return boot Secure with existing hardware DE451 13 Using a crisscross pattern tighten the Allen head cap screws to specifications then tighten the two tamper proof torx head cap screws to specifica tions 14 Connect the fuel hoses to the fuel rail then con nect the crankcase breather hose DE295A 15 Connect the oil pressure swi...

Page 44: ...alve cover DE294A 6 Remove the fuel hoses from the fuel rail then plug or close off the hoses to prevent fuel leakage DE295A 7 Remove eight standard torx head cap screws from the valve cover then using Torx Head Screw driver 30 p n 0644 344 remove the two tamper proof torx head cap screws 8 Remove four Allen head machine screws securing the fuel rail to the unit injectors then remove the fuel rail...

Page 45: ...instruments special training and an extremely clean environment clean room there fore Arctic Cat recommends injector service be per formed by a qualified diesel injection service facility Installing 1 Thoroughly clean the injector bores in the cylinder head then dry with compressed air DE567A NOTE A small round wire brush can be used to clean injector bores and seating surfaces 2 Clean the unit in...

Page 46: ...ring sealing surface on the injector tip taking care not to damage the injector tip DE565A NOTE A soft brass wire brush is recommended for cleaning injector seating surfaces 6 Orient the flame washer so the double ribs are directed toward the injector tip then install the copper washer on the injector DE569A DE570 NOTE A small amount of lithium grease applied to the washers will aid in keeping the...

Page 47: ...the second injector DE328 11 Install the injection control rack by first engaging the governor linkage sleeve then secure to the injection pump fuel controls with the pivot screws Tighten to specifications DE534A DE327 12 Install the fuel spring DE292 13 Using new O rings install the fuel rail and secure with four Allen head machine screws Tighten to specifications AT THIS POINT If injectors were ...

Page 48: ...om the air intake hose then start the engine and check for normal engine operation and look for any fuel or oil leaks 19 Install the air filter assembly and air diverter Tighten all hose clamps securely 20 Install the front body panel front rack and seat see Section 8 VALVE CLEARANCE ADJUSTMENT NOTE If the engine has been disassembled pro ceed to step 4 If the primary objective is to adjust the va...

Page 49: ... cylinder is at TDC as shown in the following illustration DE557A 5 Using an appropriate thickness gauge check the clearance between the camshaft follower and cam shaft DE642A 6 To adjust the clearance loosen the jam nut A then rotate the adjuster B to obtain the specified clearance C DE429A 7 When proper clearance is attained tighten the jam nut A while holding the adjuster B then tighten the jam...

Page 50: ...iming use the following proce dure 1 Remove the valve cover and fuel rail see Unit Injectors in this sub section 2 Install the Timing Fuel Block p n 0444 234 on the injector using the eccentric gasket over the check valve in place of the O ring DE572 DE444A 3 Connect a suitable container filled with clean die sel fuel to the supply fitting using an inlet hose then place a small cup under the bleed...

Page 51: ... aligned timing is correct proceed to step 9 If marks are not aligned the injector timing must be adjusted Adjust injector timing using the following procedure 8 Observe the position of the reference mark D and the 13 BTDC mark B and note early or late injector timing NOTE If the reference mark D is left of the 13 BTDC mark B injector timing is early If it is to the right injector timing is late A...

Page 52: ...the engine 180 clock wise using reference mark C and repeat steps 4 8 DE563A 10 Remove the timing fuel block and eccentric gas kets then install the fuel rail with four new O rings and tighten the mounting screws to speci fications DE534B DE405A 11 Install the valve cover using a new gasket and new oil return boot Tighten the cap screws to specifi cations using a crisscross pattern CYLINDER HEAD A...

Page 53: ...d all rocker arms in valve closed position 8 Remove the three nuts securing the rocker arm shaft then using rubber bands or a large O ring secure the rocker arms together DE307 9 Lift the rocker arm assembly from the cylinder head Account for three washers DE584 10 Remove the six cap screws securing the cylinder head to the engine block and remove the cylinder head assembly Account for six flat wa...

Page 54: ...t damage to the pre combustion chambers then using the special Allen head tool remove the pre combustion chamber ring nuts DE310A DE324 AT THIS POINT If the cylinder head is being removed to allow removal of engine block components no further dis assembling is required Proceed to Cleaning and Inspecting in this sub section If the cylinder head is to be serviced or replaced proceed to Disassem blin...

Page 55: ...ide to side and end to end DE302 NOTE If cylinder head warpage is present the cylinder head must be planed by a qualified machine shop Pre combustion chambers must be removed to plane the head 3 Inspect the valve springs for surface cracks and fractures 4 Using a calipers measure the free length of the valve springs The measurement must be equal to or greater than minimum specifications DE318 5 Ch...

Page 56: ...eplacement Arctic Cat recommends that the com ponents be taken to a qualified machine shop for ser vicing Assembling Valves 1 Thoroughly clean all valve components in parts cleaning solvent then dry with compressed air 2 Place new valve seals in clean engine oil and soak for five minutes then using a suitable installation tool install the seals on the valve guides DE320A 3 Apply clean engine oil t...

Page 57: ... the glow plug bore NOTE To simplify installation orientation of the pre combustion chamber install the chamber on the removal tool then place into the head Remove the tool after completing step 3 DE326A DE321A 3 Insert the pre combustion chamber alignment tool into the glow plug bore while slightly shifting the chamber until the alignment tool properly engages the opening in the chamber then comp...

Page 58: ...on to cylinder head clear ance To select the correct cylinder head gasket use the following procedure A Rotate the crankshaft until one of the pistons is at top dead center TDC as indicated by a dial indicator DE330 B Using a depth micrometer measure and record piston protrusion above the cylinder deck plane DE386 C Use steps A and B to measure and record piston protrusion on the other piston D Us...

Page 59: ...not exceed 91 mm 6 Apply clean engine oil to the threads of the cylin der head bolts washers the bolt heads and the thrust areas then install and hand tighten 7 Tighten the head bolts to 5 0 kg m 36 ft lb in 1 0 kg m 7 ft lb increments using the pattern shown DE575B 8 In the same pattern tighten each cylinder head bolt 90 then tighten an additional 90 using the same pattern DE575C 9 Install the ro...

Page 60: ...ove the front rack then remove the front body panel see Section 8 2 Remove the negative battery cable from the bat tery 3 Remove the shift linkage from the shift arm and swing the linkage forward Account for an E clip bushing and washer 4 Loosen the alternator mounting cap screws and remove the alternator belt 5 Remove four cap screws securing the crankshaft pulley to the timing belt drive pulley ...

Page 61: ...ean and remove burrs as required DE232 3 Inspect the timing belt cover for cracks seal dam age or signs of oil leakage If oil is present locate and repair any leaks Thoroughly clean all oil from the timing belt cover and pulleys Installing 1 Check that the reference mark C on the timing belt drive pulley is aligned with the reference mark D on the oil pump housing and the reference mark A on the c...

Page 62: ...using a suitable torque wrench position the handle 90 to the tensioner tab and apply 2 0 kg m 14 5 ft lb of torque Tighten the timing belt idler nut securely DE234A DE222A 4 Rotate the engine in the direction of rotation clockwise facing the timing belt three full revo lutions then loosen the idler nut and repeat step 3 5 After repeating step 4 two times tighten the tim ing belt idler nut to speci...

Page 63: ...nt rack Tighten the existing hardware securely WATER PUMP Removing 1 Remove the timing belt see Left Side Compo nents in this section 2 Drain the coolant see Section 4 3 Remove the lower radiator hose and the coolant bypass hose from the water pump then remove four cap screws securing the water pump and remove the water pump 4 Thoroughly clean all gasket material from the engine block and water pu...

Page 64: ...rom the oil pump housing being careful not to mar or scratch the seal bore DE238 5 Thoroughly clean the seal bore making sure it is free of all oil and sealant and free of any nicks or burrs 6 Soak a new oil seal in clean engine oil for approxi mately 30 minutes then using an appropriate driver drive the seal into the oil pump housing until flush with the outer seal bore DE237 NOTE If there is a g...

Page 65: ...ainst the engine block then secure with the existing hardware and tighten to specifications Note the correct cap screw locations DE227A 6 Install the alternator bracket and secure with the three cap screws Tighten securely 7 Install the key in the crankshaft then install the timing belt drive pulley 8 Install the timing belt see Left Side Components in this section ALTERNATOR REGULATOR Removing 1 ...

Page 66: ...left side engine cover and seat making sure the seat latches securely Right 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 does not have to be removed from the frame for this procedure FLYWHEEL PTO...

Page 67: ...ssembly on a flat sur face with the PTO side up then using a cold chisel and hammer score the ring gear in several loca tions around the circumference DE591 2 Turn the flywheel ring gear assembly over and support on a suitable block so that the ring gear is free to be driven from the flywheel then using a punch and hammer tap the ring gear off the fly wheel DE592 3 Lay the flywheel on a flat surfa...

Page 68: ...ase 1 Remove the gear shift position switch Account for two contact pins and two springs CD997 2 Remove the cap screws securing the secondary output shaft bearing housing then tap the housing with a rubber mallet and remove Account for two alignment pins DE117A 3 Mark the shift shaft to align with a reference on the shift arm them remove the shift arm DE119A 4 Remove the shift shaft housing Accoun...

Page 69: ... DE126A 8 From the right side remove the cap screws secur ing the transmission halves together then lay the transmission on a suitable bench with the right side down DE130A 9 Using a rubber mallet lightly tap the left side gear case away from the right side gear case leaving all components in the right side Account for any washers that may stick to the left side gear case and return to the proper ...

Page 70: ...veshaft D NOTE The shift forks are identical therefore they may be used in either location However it is advisable to return mating parts to their original positions during assembling DE139 14 Remove the countershaft assembly E Account for a thrust washer on each end noting the different sizes DE142A 15 Remove the reverse idler gear F Account for the axle a bushing and two thrust washers DE143A NO...

Page 71: ...recede this procedure 19 Remove the retaining C rings in the output yoke then using an appropriate universal joint service tool separate the front drive yoke and bearing uni versal joint from the rear yoke DE146 20 Remove the retaining nut from the front driveshaft and remove the front drive yoke Account for a washer seal bearing and shim DE147 21 Remove the retaining nut from the rear driveshaft ...

Page 72: ...nap ring then remove the reverse dog and reverse dog drive bushing DE152 DE153 25 Remove the snap ring securing the reverse gear then remove the reverse gear Account for a thrust washer and the reverse gear bearing and bushing DE154 DE155 26 Remove the low gear locking washer then rotate and remove the splined low gear retainer Back to TOC Back to Section TOC Next Back ...

Page 73: ...cessive wear worn splines bearing surface discoloration or chipped gears DE158A DE140A 2 Inspect all shift dogs for chips rounded dogs worn splines or discoloration DE162 DE177 3 Inspect all idler gears bushings thrust washers and shafts for abnormal wear discoloration chip ping or galling DE143 Back to TOC Back to Section TOC Next Back ...

Page 74: ...6 Inspect sliding shift dogs for binding on splines chipped or distorted splines or discoloration DE160 7 Inspect shift forks for excessive wear galling of wear surfaces or discoloration DE165 8 Inspect shift cam assembly for worn cam grooves broken springs damaged thrust bearings or thrust washers DE138 9 Inspect transmission case halves for loose bear ings discolored bearing pockets filings or d...

Page 75: ...solvent then dry with compressed air Assembling Countershaft 1 Place the thrust washer on the splined end of the countershaft then install the low driven gear bush ing and bearing DE155A DE158B 2 Install the low driven gear onto the bearing with the shift dog slots directed toward the fine splined section of the countershaft then secure with a splined washer and lock washer DE184 3 Place a splined...

Page 76: ...se shift dog and splined bushing onto the shaft then secure with a snap ring DE187A 6 Install the countershaft drive gear and thrust washer 7 Install the high low shift dog with the raised lugs directed toward the low driven gear DE189A DE190A 8 Install the high driven gear thrust washer bushing and bearing then install the high driven gear and thrust washer DE191A DE166A Back to TOC Back to Secti...

Page 77: ...f the output driven shaft then secure with a washer and nut Tighten to specifications and stake the nut to the shaft DE147 12 Install the rear drive gear bearing oil seal and out put drive flange to the rear of the output driven shaft then secure with a washer and nut Tighten to specifications and stake the nut DE149A DE148A NOTE The drive bevel gear and secondary out put shaft assemblies are now ...

Page 78: ...shaft DE179 DE140 DE192A 3 Install the assembled countershaft assembly taking care to position a washer on each end DE142 DE193A 4 Install the reverse shift fork then install the gear shift shaft making sure the thrust bearing and races are positioned correctly and the washers are in place DE138A Back to TOC Back to Section TOC Next Back ...

Page 79: ...f Three Bond Sealant to the mating surface of the right side gear case then make sure that the alignment pins and washers are positioned as shown and join the gear case halves Do not force the gear case halves together DE133D 8 From the right side install the gear case cap screws and using a crisscross pattern tighten until the gear case halves are finally joined turning the shafts frequently to a...

Page 80: ...securely DE119 12 Apply Three Bond Sealant to the secondary output shaft bearing housing then install on the transmis sion and tighten securely DE117A 13 Install two springs and two contact pins in the end of the gear shift shaft then install the gear shift position switch with a new O ring and tighten the cap screws securely DE116A DE115 14 Install the left and right transmission mounting bracket...

Page 81: ...ion 4 Remove the cylinder head assembly see Left Side Components in this section 5 Remove the oil pump assembly see Left Side Components in this section 6 Remove the cap screws securing the oil pan assembly then remove the oil pan assembly Account for two O rings and a gasket DE332A 7 Remove the four cap screws securing the water pump to the engine block then remove the pump assembly DE267 8 Measu...

Page 82: ...he cap Account for one bear ing insert DE600 11 Rotate the crankshaft carefully until the second connecting rod is at BDC then using a large wooden dowel or hammer handle carefully push against the first connecting rod until the pis ton connecting rod assembly is free of the cylinder bore DE599A DE394 12 Attach the connecting rod cap with bearing inserts and loosely install the cap screws keeping ...

Page 83: ... DE435A 17 Mark the main bearing caps and engine block for proper orientation then remove the cap screws securing the main bearing caps to the main bearing saddles in the engine block DE335C 18 Lightly rock the bearing caps in the saddles while applying pressure away from the crankshaft until the bearing cap is free of the engine block Account for a bearing insert for each cap and two thrust beari...

Page 84: ...d Inspecting 1 Clean all gasket material sealant varnish and car bon from the engine block mating and sealing sur faces DE338 2 Remove the main bearing inserts from the main bearing caps and saddles then set the caps aside in order NOTE If main bearing inserts are to be used again mark their locations for correct positioning during installing 3 Using appropriate thread taps clean up the main beari...

Page 85: ...ently to be salvaged Example 2 Pp 0 82 mm 0 032 in Vd 0 30 mm 0 012 in 0 82 0 30 1 12 mm 0 044 in Ppf 1 12 mm 0 044 in Using the preceding chart it can be determined that no gasket would be available to allow sufficient pis ton to cylinder head clearance therefore the engine block must be replaced D If engine block is not serviceable it must be replaced with a new block 6 Thoroughly clean the engi...

Page 86: ...ore is severely scored or out of round the cylinders must be bored DE398B 9 Lightly coat all non painted surfaces thread bores and cap screw threads with clean engine oil DE398 DE356 10 Wash the crankshaft connecting rods and oil pan and cover in parts cleaning solvent then dry with compressed air 11 Using a suitable micrometer carefully measure the crankshaft main bearing and connecting rod jour ...

Page 87: ...dles then install the bearing inserts into the correct locations DE376 14 Install the main bearing caps and tighten to speci fications then being careful not to mar the inserts measure the main bearing bores using an appropri ate inside micrometer snap gauge Record the measurements DE609 DE610 15 Measure the crankshaft main bearing journals and record the measurements CAUTION Always support the cr...

Page 88: ...appropriate inside micrometer measure the inside diameter of the connecting rod bearing insert It must be within specifications or the bear ings or connecting rod must be replaced DE612 20 Measure the inside diameter of the connecting rod piston pin bushing It must be within specifica tions DE366 CAUTION If a vise is used to secure the connecting rod it must have brass copper or hardwood jaws to p...

Page 89: ...ng to ring land clearance using new piston rings If ring to ring land clearance is excessive new pistons must be installed DE367 25 Using a suitable outside micrometer measure pis ton skirt diameter at a distance of 9 mm 0 350 in from the bottom of the skirt and 90 from the pis ton pin axis Pistons and cylinder measurements must be within specifications as listed in the fol lowing chart Class mark...

Page 90: ...e oriented in the reliefs DE376A 2 Install the thrust bearing inserts into the rear main bearing saddle using a small amount of oil soluble grease to hold them in place DE628A 3 Install the lower main bearing inserts into the main bearing caps then install the thrust bearing inserts into the rear main bearing cap using oil soluble grease to hold in place DE431 4 Apply a liberal amount of clean eng...

Page 91: ...he main bearing caps to specifications in 1 0 kg m 7 0 ft lb increments DE335 10 Rotate the crankshaft to make certain that no bind ing exists 11 If pistons were removed from connecting rods install the pistons onto the connecting rods making sure the piston pin retainer clips are properly seated and the open ends are orientated facing downward DE371A 12 Check piston ring gap by installing the rin...

Page 92: ...ark ings on the ring directed toward the top of the piston C Install the 1st top compression ring in the top ring groove with the TOP or UP markings on the ring directed toward the top of the piston NOTE The top compression ring is full chrome silver and the middle compression ring has a par tial chrome band on the bottom side Both rings have a chamfered inner radius The chamfer must be directed u...

Page 93: ...op of the piston until the connecting rod is seated on the crankshaft DE436 21 Apply clean engine oil to the crankshaft journal and connecting rod cap bearing insert then mak ing sure the connecting rod cap is correctly ori ented to the connecting rod install the rod cap and secure with the cap screws Tighten to specifica tions in 1 0 kg m 7 0 ft lb increments DE437 WARNING NEVER force the piston ...

Page 94: ... the two hollow studs and spacers making sure to install the two hollow studs at the outside cor ners on the crankshaft pulley side then using a crisscross pattern tighten to specifications DE442A 29 If the oil pan cover was removed place two new gaskets onto the oil pan then install the oil pan cover and secure with the Allen head cap screws Tighten in a crisscross pattern to specifications DE442...

Page 95: ... and O rings be installed whenever servicing the ATV NOTE If the engine transmission was removed as an assembly proceed to Engine Transmission in this sub section If only the transmission was removed use the following procedure to install TRANSMISSION 1 If the V belt housing was removed from the crank case support the engine on blocks and using a new gasket install the V belt housing and tighten t...

Page 96: ...ten the nut to specifications 7 Install the movable drive clutch face and V belt cover see Section 2 ENGINE TRANSMISSION 1 Attach a suitable lift and place the engine trans mission assembly into the frame from the left side tilting the engine forward sufficiently to clear the frame tube DE084A 2 Maneuver the engine transmission into position in the frame then install the front propeller shaft into...

Page 97: ... to the front engine mount Do not tighten at this time DE087A 6 Install the cap screws washers and nuts in the left rear right rear and upper right engine mounts DE085A DE090A DE088A 7 Tighten all engine mounting cap screws and nuts to specifications 8 Install the transmission level stick mount using a new O ring then connect the throttle cable and thread the throttle cable housing into the bracke...

Page 98: ...l the muffler and secure to the exhaust pipe with two springs making sure the grafoil seal is in place then tighten the exhaust pipe nuts to specifi cations DE586 12 Connect the wiring connectors to the temperature sensor oil pressure sensor gear shift position switch connector and voltage regulator then con nect the starter solenoid glow plug power wire and alternator positive wire DE104A DE067A ...

Page 99: ...assembly then install the V belt cooling boots to the V belt housing DE076A 16 Connect the V belt cooling fan connector DE518A 17 Install the air filter assembly and secure with four cap screws then connect all hoses and secure with hose clamps Tighten all hardware securely DE074A 18 Install the coolant filler neck on the thermostat housing and tighten the hose clamp securely then install the uppe...

Page 100: ...kage to the transmission shift arm and secure with the E clip DE064A 22 Install the front body panel and front rack then install the left and right footrests see Section 8 23 Pour the recommended coolant engine oil and transmission lubricant into the respective filler necks see Section 2 24 Install the battery and connect the positive battery cable then connect the negative cable 25 Install the se...

Page 101: ...obstructed 4 Fuel pump defective 5 Fuel solenoid valve not opening 1 Clean vent hose 2 Clean replace hose 3 Replace fuel filter 4 Replace fuel pump 5 See Section 5 Fuel Solenoid Problem Engine stalls easily Condition Remedy 1 Valve clearance out of adjustment 1 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve spring s weak broken 3 ...

Page 102: ...t worn 5 Fuel injector obstructed 6 Injector timing incorrect 1 Adjust clearance 2 Replace service seats valves 3 Replace guides 4 Replace arms shafts 5 Replace fuel injector 6 Time injectors Problem Engine runs poorly at high speed Condition Remedy 1 Valve springs weak 2 Valve timing out of adjustment 3 Cams rocker arms tappets worn 4 Air cleaner element obstructed 5 Fuel hose obstructed 6 Fuel p...

Page 103: ...place arms shafts 7 Clean element 8 Drain excess oil change oil 9 Time injectors 10 Replace fuel filter Problem Engine overheats Condition Remedy 1 Air filter restricted 2 Oil low 3 Fuel incorrect 4 Oil pump defective 5 Oil circuit obstructed 6 Coolant level low 7 Fan malfunctioning 8 Fan switch malfunctioning 9 Thermostat stuck closed 10 Radiator hoses cap damaged obstructed 1 Clean replace air f...

Page 104: ...t Injectors 4 3 Injector Timing 4 3 Fuel Filter 4 3 Fuel Solenoid Assembly 4 3 Throttle Cable Free Play 4 4 Fuel Tank 4 4 Fuel Vent Hoses 4 5 Oil Filter Oil Pump 4 5 Testing Oil Pump Pressure 4 5 Liquid Cooling System 4 5 Radiator 4 6 Hoses Thermostat 4 7 Fan 4 7 Water Pump 4 7 Troubleshooting 4 8 Back to TOC ...

Page 105: ...er recirculates or is returned to the fuel tank via the fuel return hose Fuel flow is shut off when the ignition switch is turned to the OFF position A fuel solenoid valve is located on the fuel filter head and opens the valve whenever a 12 DC volt current is applied to the solenoid Lift Pump REMOVING 1 Remove the banjo fitting bolts securing the fuel hoses to the lift pump then remove the two nut...

Page 106: ...splash panel then remove the V belt cooling boot from the V belt housing DE061A 2 Locate the fuel solenoid mounted on top of the fuel filter head then disconnect the spade connec tor from the solenoid DE647B 3 Remove the banjo fitting bolts A and B and remove the fuel solenoid Account for four crush washers DE647A INSTALLING 1 Using new crush washers secure the fuel solenoid to the filter housing ...

Page 107: ...ll contaminated fuel from the fuel tank then thoroughly wash the tank out with hot soapy water 3 Dry the tank interior with compressed air Repeat steps 2 and 3 until all contaminants are removed 4 Back flush the fuel screen with hot soapy water and dry with compressed air NOTE If any pin holes are noted in the fuel screen replace the fuel level sensor assembly 5 Inspect the tank cap and filler nec...

Page 108: ... too heavy engine oil weight see Section 1 clogged oil passage clogged oil filter or improper installation of the oil filter Liquid Cooling System The cooling system should be inspected daily for leak age and damage Also the coolant level should be checked periodically To check the cooling system see Section 2 DRAINING COOLANT The cooling system does not have a drain therefore coolant must be remo...

Page 109: ...nt for the grommets and collars 7 Remove the fan fan shroud assembly from the radiator CC863 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Flush the radiator with water to remove any con taminants 2 Inspect the radiator for leaks and damage 3 Inspect all hoses for cracks and deterioration 4 Inspect all fasteners and gromme...

Page 110: ...clamps should be replaced every four years or 4000 miles INSTALLING 1 Place the thermostat and O ring into the thermo stat housing then secure the thermostat housing to the cylinder head with the two cap screws 2 Install the crossover coolant hose onto the water pump and engine water inlet Secure with the two hose clamps 3 Slide the upper hose onto the thermostat housing and radiator Secure with t...

Page 111: ...ling or low speed impaired Condition Remedy 1 Fuel filter plugged 1 Replace fuel filter Problem Medium or high speed impaired Condition Remedy 1 Governor spring broken 2 Fuel filter obstructed 3 Throttle cable out of adjustment 1 Replace speed governor spring 2 Replace filter 3 Adjust throttle cable Back to TOC Back to Section TOC Back ...

Page 112: ...y 5 4 Fan Motor 5 5 Fuse Block Power Distribution Module 5 5 Fuses 5 6 Electronic Speedometer Speed Sensor 5 6 Ignition Switch 5 7 Handlebar Control Switches 5 7 Front Drive Selector Switch 5 8 Front Drive Selector Actuator 5 8 Differential Lock Switch 5 9 Starter Starter Solenoid 5 9 Starter Relay 5 10 Alternator Regulator 5 10 Neutral Start Front Drive Actuator Start in Gear Differential Lock 2W...

Page 113: ...ust show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse receptacle connec tor or the main wiring harness Brakelight Switch Auxiliary The switch connector is the two prong connector on the brake switch lead above the transmission NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Side 1 Set the meter selector to the DC Voltage positi...

Page 114: ...1 Set the meter selector to the OHMS position 2 Connect the red tester lead to one black wire then connect the black tester lead to the other black wire AR621D 3 When the lever is compressed the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resistance replace the switch Cooling Fan Switch 1 Connect the meter leads selector in OHMS posi tion to the cooling fan switch te...

Page 115: ... located under the seat The glow plug controller relay applies 12 DC volts to the glow plugs in the pre com bustion chambers to aid in cold starting Heating time is determined by the ECT thermistor signal and will vary from 0 seconds warm engine to approximately 30 seconds cold engine NOTE The glow plug controller relay is not a ser viceable component To test the controller relay use the following...

Page 116: ...must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resistance troubleshoot or replace the switch component the connector or the switch wiring harness NOTE To determine if the fan motor is good connect the blue wire from the fan connector to a 12 volt DC power supply then connect the black wire from the fan connector to ground The fan should operate Fuse Block Power Distribution M...

Page 117: ... on the meter leads connect the red tester lead to the voltage lead V then connect the black tester lead to the ground lead G CD885A 3 Turn the ignition switch to the ON position 4 The meter must show 6 DC volts 5 Leave the black tester lead connected then con nect the red tester lead to the signal lead S pin 6 Slowly move the ATV forward or backward the meter must show 0 and 6 DC volts alternatel...

Page 118: ...leshoot or replace the switch component the connector or the switch wiring harness Handlebar Control Switches The connector is the yellow one next to the steering post To access the connector the steering post cover and the right side fender splash shield must be removed see Section 8 NOTE These tests should be made on the top side of the connector RESISTANCE HI Beam 1 Set the meter selector to th...

Page 119: ...does not show as specified replace the front drive selector switch VOLTAGE NOTE The battery must be connected when performing voltage tests 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the negative bat tery terminal 3 Connect the red tester lead to the red wire on the harness side of the connector 4 Turn the ignition switch to the RUN position 5 The meter ...

Page 120: ... the ATV slightly to engage the differential lock fully NOTE The 4WD and the LOCK icons on the LCD should illuminate CD576 CF094C 4 If the differential lock engages front wheels locked and the voltage does not drop to 0 the switch is faulty and must be cleaned or replaced Starter Starter Solenoid NOTE The starter is not a serviceable compo nent and must be replaced as an assembly Before replacing ...

Page 121: ...er Relay 1 Remove the seat then using the multimeter set to the DC Voltage position check the relay as fol lows 2 Connect the red tester lead to the battery terminal then connect the black tester lead to the starter solenoid cable connection on the starter relay The meter must show battery voltage DE002B NOTE Make sure that the ignition switch is in the ON position transmission in neutral brake lo...

Page 122: ...egulator control plug in DE519B 3 Loosen the alternator adjuster cap screw A and the pivot bolt B then remove the alternator drive belt DE519C DE103C 4 Remove the adjuster cap screw and pivot bolt and remove the alternator NOTE The alternator regulator is not a service able part therefore it must be replaced as an assembly INSTALLING 1 Place the alternator regulator into position on the engine the...

Page 123: ...nectors LO beam The meter must show battery voltage 4 With the dimmer switch in the HI position test the two inside connectors HI beam The meter must show battery voltage NOTE If battery voltage is not shown in any test inspect the fuses battery main wiring har ness connectors or the left handlebar switch Taillight Brakelight The connector is the 3 prong one located under the rear fender assembly ...

Page 124: ...olenoid see Sec tion 4 Troubleshooting Problem Charging unstable Condition Remedy 1 Battery connections loose or corroded 2 Alternator belt loose 3 Alternator regulator failing 1 Clean and tighten connections 2 Tighten replace belt 3 Replace alternator assembly Problem Starter button not effective Condition Remedy 1 Battery charge low 2 Switch contacts defective 3 Starter solenoid defective 4 Star...

Page 125: ...TS Drive System 6 2 General Information 6 2 Front Drive Actuator 6 3 Front Differential 6 4 Drive Axles 6 17 Rear Gear Case 6 21 Hub 6 22 Hydraulic Brake Caliper 6 24 Troubleshooting Drive System 6 25 Troubleshooting Brake System 6 26 Back to TOC ...

Page 126: ...ightness wheel bearing damage gear case lubricant contamination low lubricant level seal leakage CV joints or selector arm NOTE Small metallic particles will collect on the magnetic drain plug as a normal part of break in and will also give a metallic cast to drained lubricant Contamination would include large particles or water which gives a milky look to the lubricant NOTE Lubricant on a new pin...

Page 127: ...emove the mounting cap screw from the driveshaft side of the actuator AG926 3 Remove the mounting cap screw from below the actuator on the suspension side AG927 4 Loosen but do not remove the mounting cap screw at the front of the actuator then slide the actuator to the rear enough to clear the slotted mounting tab and the selector shaft AG928 INSTALLING 1 Lubricate the O ring on the actuator then...

Page 128: ...levate the wheels 2 Remove the drain plug and drain the gear lubricant into a drain pan then reinstall the plug CF107B 3 Remove the front wheels then remove the front inner fender panels 4 Compress the hand brake then engage the brake lever lock 5 Remove the cotter pin securing the hex nut then remove the hex nut and washer KX041 6 Release the brake lever lock NOTE It is not necessary to remove th...

Page 129: ...axle to not allow it to drop or hang 13 Remove the lower shock bolts Account for the lock nuts then move the shocks aside and secure them with a strap AF897D 14 Remove the upper A arm lock nuts and cap screws then remove the A arms AF610D 15 Using a slide hammer remove the front axles AF899D 16 Remove the three cap screws securing the front drive flange to the front drive coupler CAUTION The axle ...

Page 130: ... then place the differential on its right side and remove it from the frame KX159 Disassembling Input Shaft NOTE This procedure can be performed on a rear gear case however some components may vary from model to model The technician should use discretion and sound judgment 1 Using a T 40 torx wrench remove the screws securing the pinion housing PR261A 2 Using a rubber mallet remove the housing Acc...

Page 131: ...Remove the snap ring securing the input shaft bearing 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 Back to TOC Back to Section TOC Next Back ...

Page 132: ...e input shaft into the pinion housing then secure with a snap ring KX210A 5 Place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to specifications NOTE If a new gear case housing is being installed tighten the cap screws to 3 5 4 3 kg m 25 31 ft lb CD103 Disassembling Pinion Gear NOTE This procedure can be performed on a rear gear cas...

Page 133: ...ore than one recessed location 4 Remove the splined coupler shifter fork pin and spring of the differential lock assembly and set aside Note position of parts for assembling pur poses KX175 5 Make match marks on the left bearing housing and differential housing then remove the plate and account for a shim Mark the shim as left side KX176 KX177 KX178 6 Place the differential with the open side down...

Page 134: ... pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar and a bearing CC879 NOTE If gears are being replaced use the exist ing shims The numbers are scribed onto the gears the ring gear has the number on the oppo site side of the gears and the pinion gear has the number on the end of the pinion gear shaft by the splines If no number is present it should b...

Page 135: ...d end play to be within a range of 0 10 0 20 mm 0 004 0 008 in If not within specification range reselect shim until backlash specification range can be verified 4 Prior to final assembling apply molybdenum dis ulfide grease to all oil seal lips 5 Prior to final assembling prelubricate journal on pinion assembly with SAE 80W 90 hypoid gear lubricant prior to pressing assembly into gear case housin...

Page 136: ...then install the gasket CC893 7 Place the input housing onto the gear case hous ing then secure with the existing cap screws Tighten to specifications NOTE If a new gear housing is being installed tighten the cap screws to 3 5 4 3 kg m 25 31 ft lb CD103 CD110 8 Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear Install...

Page 137: ...he cap screws to specifications NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new gear case housing is being installed tighten the cap screws to 3 5 4 3 kg m 25 31 ft lb Removing Needle Bearing NOTE Removing the needle bearing is rarely necessary Avoid removing the needle bearing unless the bearing is clearly damaged NOTE This procedure can be performed on a rear gear c...

Page 138: ... ing CC888 2 Using a suitable driver install the needle bearing into the gear case housing making sure the bearing is seated NOTE Do not push the bearing too far into the housing CC889 3 Install the pinion shaft and secure with the existing 48 mm lock collar Tighten to specifications 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...

Page 139: ...lling the seal apply grease to the seal outside diameter 4 Install the seal into the housing pressing evenly on the outside edge until the seal is seated CD018 5 Repeat steps 1 4 for the opposite side INSTALLING DIFFERENTIAL 1 Place the differential into position on the frame and install the cap screws washers and flex lock nuts Tighten to specifications 2 Align the front drive flange and the fron...

Page 140: ... this sec tion 7 Secure the upper A arms with cap screws and lock nuts Tighten to specifications AF610D 8 Secure the lower shock eyelets with cap screws and lock nuts Tighten to specifications AF897D 9 Secure the tie rods ends with the lock nuts Tighten to specifications then install and spread the cotter pins AF896D AF895D 10 Making sure that each caliper has the 0 76 mm 0 030 in spacer washers b...

Page 141: ...ck nut Once a lock nut has been 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 9 Place a drain pan under the ATV to contain any oil leakage then using a slide hammer remove the drive axle AF935 REMOVING FRONT DRIVE AXLE NOTE For removing a front drive axle see Front Differential i...

Page 142: ... bearing ring to the shaft Note the direction of the bearing for assembling purposes CD023 4 Note the difference inside each bearing ring end for assembling purposes then remove the bearing ring NOTE The recess 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 ri...

Page 143: ...shaft with the new clamps positioned as shown Note the differ ent sized clamps from removal NOTE The boot is positioned correctly when the small end of the boot seats down into the recessed groove CD754 10 Using a CV Boot Clamp Tool p n 0444 120 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 corr...

Page 144: ... for correct position ing of the four clamps Also inspect the boots for being correctly positioned on the shaft INSTALLING REAR DRIVE AXLE 1 Slide the drive 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 ...

Page 145: ...hten securely then install and spread a new cotter pin 4 Slide the hub w brake disc into position in the steering knuckle followed by a washer and hex nut Tighten finger tight at this time 5 Install the brake caliper on the steering knuckle Tighten to specifications then pump up the hand brake lever and engage the brake lever lock 6 Tighten the hub hex nut from step 4 to specifica tions then insta...

Page 146: ...s section 4 Install the left side rear A arms see Rear A Arms in Section 7 Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the cotter pin from the nut NOTE During assembly new cotter pins should be installed KX041 3 Remove the flange nut securing the hub 4 Remove the brake caliper PR243A 5 Remove the hub assembly 6 Remove the four cap screws sec...

Page 147: ...ssembly onto the shaft CD009 4 Secure the hub assembly with the nut Tighten only until snug 5 Secure the brake caliper to the knuckle with the two cap screws Tighten the auxiliary caliper to specifications Tighten the hydraulic caliper to specifications PR243A 6 Tighten the hub nut from step 4 to specifications then install and spread a new cotter pin making sure each side of the pin is flush to t...

Page 148: ...and account for the brake caliper O ring Do not remove the piston from the caliper PR239B 6 Plug the fluid port with a suitable plug to prevent contamination during cleaning PR240A CLEANING AND INSPECTING 1 Clean all caliper components except the brake pads with parts cleaning solvent 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Section 2 ASSEMBLING INST...

Page 149: ...rive System 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 damaged 4 Coupling joint serration worn damaged 5 Front drive driven bevel gears broken...

Page 150: ... 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 cracke...

Page 151: ...7 1 7 SECTION 7 SUSPENSION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 Front A Arms 7 3 Rear A Arms 7 5 Wheels and Tires 7 7 Troubleshooting 7 8 Back to TOC ...

Page 152: ...cement is necessary 1 Thoroughly clean all shock absorber components 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock rods sleeves bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber spring over the shock absorber compress the spring and install the retainer 2 Place bushings and sleeves w...

Page 153: ... pin and slotted nut securing the tie rod end to the knuckle then remove the tie rod end from the knuckle AF618D 7 Remove the cap screws securing the ball joints to the knuckle AF628D 8 Tap the ball joints out of the knuckle then remove the knuckle 9 Remove the lower shock absorber eyelet from the upper A arm 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remove the snap ring ...

Page 154: ...joint into the A arm and secure with the snap ring AF616D 2 Install the A arm assemblies into the frame mounts and secure with the cap screws Only fin ger tighten at this time AF610D 3 Route the brake hose through the upper A arm shock absorber mount then secure the hose to the A arm with a cable tie and grommet DE054A 4 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut ...

Page 155: ...cifications 12 Install a new cotter pin and spread the pin to secure the nut CD008 13 Install the wheel and tighten to specifications 14 Remove the ATV from the support stand Rear A Arms REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut ...

Page 156: ...w lock nuts Only finger tighten at this time 2 Slide the knuckle onto the drive axle and into posi tion on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to specifications 3 Tighten the hardware securing the A arms to the frame mounts from step 1 to specifications 4 Apply grease on the drive axle splines then install the hub assembly onto the drive axle ...

Page 157: ...ure washer 2 Clean the tires with soap and water 3 Inspect each wheel for cracks dents or bends 4 Inspect each tire for cuts wear missing lugs and leaks INSTALLING Install each wheel on its hub Tighten to specifications NOTE Make sure each wheel is installed on its proper hub as noted in removing the rotation arrow if applicable must indicate forward direc tion of rotation AF612D CHECKING INFLATIN...

Page 158: ...g only check and adjust the brakes as necessary and recheck operation see Section 2 5 Increase the air pressure in the tires with the small est circumference measurement until all tires are equal in circumference 6 Repeat steps 4 5 as necessary to ensure proper handling Troubleshooting WARNING Do not operate the ATV if tire damage exists Problem Suspension too soft Condition Remedy 1 Spring s weak...

Page 159: ...ring Knuckles 8 4 Measuring Adjusting Toe In 8 6 Front Rack 8 8 Front Bumper Assembly 8 8 Front Rear Body Panel 8 8 Front Body Panel Side Panels 8 11 Footrests 8 14 Belly Panel 8 15 Exhaust System 8 15 Rear Body Panel Rack 8 15 Adjusting Headlight 8 16 Taillight Assembly 8 16 Seat 8 17 Troubleshooting 8 17 Back to TOC ...

Page 160: ...g post cover and remove the cover CD667 4 Unlatch the storage compartment lid then slide the storage compartment cover assembly forward and lift off 5 Remove the four cap screws securing the handle bar caps and instrument pod bracket to the steering post then move the handlebar out of the way Account for four handlebar caps 6 Remove two cap screws securing the upper steer ing post bearing to the f...

Page 161: ...earing halves bearing caps and bear ing housings for cracks or wear 7 Inspect the handlebar tube for cracks wear or unusual bends 8 Inspect the handlebar grips for damage or wear INSTALLING 1 Place the steering post into position then secure the lower bearing flange to the frame with two cap screws Tighten to specifications AL600D 2 Place the upper steering post bearings into the housings then pos...

Page 162: ... installing a grip use contact spray or alcohol to clean the inside of the grip and the handlebar of glue residue oil or any other contaminant 1 Apply a liberal amount of Handlebar Grip Adhe sive to the inside of the grip 2 Align the rivet hole in the grip with the rivet hole in the handlebar then align the notch inside the grip with the slot in the handlebar and slide the grip onto the handlebar ...

Page 163: ...ap ring mak ing sure it seats into the knuckle PR287A 2 Install the knuckle to the upper and lower ball joints and secure with the two cap screws Tighten to specifications AF760D 3 Install the tie rod end and secure with the nut Tighten to specifications then install a new cotter pin and spread the pin NOTE During assembling new cotter pins should be installed AF759D 4 Apply a small amount of grea...

Page 164: ...ss 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 CD005 3 Place the ATV in a level position taking care not to push down or lift up on the front end then turn the handlebar to the straight ahead position NOTE When measuring and adjusti...

Page 165: ...d to adjust the tie rod Also care should be taken not to disturb the handlebar position 8 Using a permanent marker of some type mark the center of each front tire at a height parallel to the belly panel AF789D 9 Measure the distance between the marks at a height parallel to the belly panel at the front side then record the measurement 10 Push the ATV forward until the marks are parallel to the bel...

Page 166: ...ont Bumper Assembly REMOVING 1 Remove the two flange bolts and lock nuts secur ing the upper bumper supports to the bumper 2 Remove the through bolt and lock nut securing the bumper to the frame then remove the bumper CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all bumper components 2 Inspect all welds for cracking...

Page 167: ...cated behind the grille CF201A CF160A 8 Remove the two cap screws and lock nuts securing the left foot peg and remove the foot peg CD782 9 Remove eight cap screws and lock nuts and one reinstallable rivet securing the right side footwell to the fenders 10 Lift and support the rear of the body to allow access to the torx head cap screws securing the front and rear body sections together then remove...

Page 168: ...V NOTE If the front and rear body panels have been separated proceed to step 2 if the panels have not been separated proceed to step 3 2 Install the torx head cap screws and lock nuts securing the front and rear body panels together Tighten securely CF213A 3 Making sure the body mounting grommets are in place position the front and rear racks then install the eight flanged cap screws and lock nuts...

Page 169: ...nnect the negative battery cable Tighten the battery terminal cap screw securely 10 Install the tool tray then install the seat Make sure the seat locks securely Front Body Panel Side Panels REMOVING 1 Remove the reinstallable rivets securing the radia tor access cover and remove the cover then remove the reinstallable rivets securing the steer ing post cover and remove the cover CD666 CD667 2 Rem...

Page 170: ...emove the shift knob retaining pin and remove the shift knob then remove the shift lever pivot axle nut and remove the axle and shift lever Account for a spring and two O rings CD779 CD780A 8 Disconnect four headlight connectors and secure the wires out of the way then disconnect the wires to the front accessory plug CD681 9 Rotate the handlebar to the full left position then lift and slide the pa...

Page 171: ...t the headlight connectors to the appropri ate headlights and the front accessory plug wires to the accessory plug CD681 3 Make sure the four rubber grommets and bushings are in place then place the front rack into position and secure with four cap screws and flange nuts Tighten securely CD679A 4 Install one cap screw and flange nut and four plas tic rivets on each side to secure the front fenders...

Page 172: ...he foot pegs to the footrests then remove the foot pegs and foot wells CD782 3 Remove the cap screws and flange nuts securing the footrests to the frame then remove the foot rests CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the footrest using a pressure washer 2 Inspect the footrest weldments for cracks or unusual ...

Page 173: ...ils on cleaning the muffler spark arrester see Section 2 INSTALLING MUFFLER 1 Place the muffler into position engaging the mounting lugs into the grommets then slide the muffler forward 2 Install the two exhaust springs Rear Body Panel Rack REMOVING 1 Remove four machine screws and flanged nuts securing the rear rack then remove the rear rack Account for four bushings CD690A 2 Remove one shoulder ...

Page 174: ...ng sure it locks securely Adjusting Headlight The headlights can be adjusted vertically and horizon tally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming To check adjust headlight beam see Section 2 Taillight Assembly REMOVING 1 Unplug the three prong connector and free the tail light wiring harness from the frame 2 Remove the torx head cap screws ...

Page 175: ...4 Wheel hub bearing worn damaged 5 Tie rod ends worn loose 6 Tires defective incorrect 7 A arm bushings damaged 8 Bolts nuts frame loose 9 Wheel stud s loose missing 1 Adjust pressure 2 Replace wheel s 3 Replace lug nut s 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts 9 Replace wheel studs Problem Steering pulling to one side Condition Reme...

Page 176: ...e 5 Axle shaft nut loose 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 9 Wheel studs loose missing 1 Replace bearings 2 Replace tires 3 Replace rim 4 Tighten replace lug nut s 5 Tighten nut 6 Replace bushing 7 Replace shock absorber 8 Tighten nut 9 Replace wheel studs Back to TOC Back to Section TOC Back ...

Page 177: ...N 9 CONTROLS INDICATORS TABLE OF CONTENTS Hand Brake Lever Master Cylinder Assembly 9 2 Throttle Control 9 3 Drive Selector 9 4 Front Differential Lock 9 4 Shift Lever 9 4 Speedometer Tachometer LCD 9 5 Back to TOC ...

Page 178: ...ch from the master cylinder housing by gently pressing it toward the pivot pin hole in the housing then lay it aside leaving the switch and wiring harness connected BC205 5 Remove the clamp screws securing the brake housing to the handlebar then remove the assem bly from the handlebar DE058A INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary ...

Page 179: ...ing holes then install the brake lever pivot pin and snap ring BC206 4 Bleed the brake system see Section 2 Throttle Control REMOVING 1 Remove the two machine screws securing the throttle control to the handlebar 2 Slide the grommet out of the lower half of the throttle control then remove the cable from the actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator ar...

Page 180: ...the desired choice To either engage or disengage the front wheels move the switch to the 4WD position or to the 2WD position 738 422A Front Differential Lock This ATV is equipped with a front differential lock The front differential lock allows the operator to mechanically lock the differential to apply equal power to both front wheels To engage the front differ ential lock rotate the handle fully...

Page 181: ...ift arm and shift lever then making sure the O rings are in place on the axle secure the shift lever to the arm with the existing axle and nut 4 Check shift lever adjustment see Section 2 then tighten jam nut A securely 5 Install the left side splash panel Speedometer Tachometer LCD REPLACING To replace the speedometer use the following proce dure 1 Remove the two reinstallable rivets securing the...

Page 182: ...10 1 10 SECTION 10 AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications 10 2 Tightening Torque General Bolts 10 3 Torque Conversions 10 3 Back to TOC ...

Page 183: ...Bolted To Torque kg m ft lb SUSPENSION COMPONENTS Front A Arm Frame 4 8 35 0 Ball Joint Cap Screw Knuckle 4 8 35 0 Shock Absorber Frame 4 8 35 0 Shock Absorber Upper A Arm 4 8 35 0 Knuckle A Arm 4 8 35 0 SUSPENSION COMPONENTS Rear A Arm Frame 5 5 40 0 Shock Absorber Upper Frame 4 8 35 0 Shock Absorber Lower Lower A Arm 2 8 20 0 Knuckle A Arm 4 8 35 0 ENGINE TRANSMISSION Transmission Mounting Plate...

Page 184: ...3 8 7 83 11 5 4 0 6 24 3 3 44 6 1 64 8 9 84 11 6 5 0 7 25 3 5 45 6 2 65 9 0 85 11 8 6 0 8 26 3 6 46 6 4 66 9 1 86 11 9 7 1 0 27 3 7 47 6 5 67 9 3 87 12 0 8 1 1 28 3 9 48 6 6 68 9 4 88 12 2 9 1 2 29 4 0 49 6 8 69 9 5 89 12 3 10 1 4 30 4 2 50 6 9 70 9 7 90 12 5 11 1 5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14 1 9 34 4 7 54 7 5 74 10 2 9...