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• Page 1
  2014 SERVICE MANUAL [ATV]…
• Page 2
  Arctic Cat ATV publications and 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.
• Page 3
  TABLE OF CONTENTS General Information …………2 Oil Filter/Oil Pump…………..91 General Information…………..2 Testing Oil Pump Pressure ……….. 91 Torque Specifications …………..2 Oil Cooler …………….92 Torque Conversions (ft-lb/N-m) ……….3 Liquid Cooling System …………92 Break-In Procedure …………..3 Electric Fuel Pump/Fuel Level Sensor ……..94 Gasoline — Oil — Lubricant …………4 Troubleshooting…………..

• Page 4: Torque Specifications

  Footrest Frame (8 mm) Gasoline (recommended) 87 Octane Regular Footrest Frame (10 mm) Unleaded SUSPENSION COMPONENTS (Front) Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) A-Arm Frame Front Differential/Rear Drive Lubricant SAE Approved 80W-90 Knuckle Ball Joint Hypoid Shock Absorber…

• Page 5: Torque Conversions (Ft-Lb/N-M)

  ENGINE/TRANSMISSION Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m Clutch Shoe** Crankshaft Clutch Cover/Housing Assembly Crankcase Crankcase Half Crankcase Half Crankcase Lower Cover (6 mm) Crankcase ft-lb ft-lb ft-lb ft-lb Crankcase Lower Cover (8 mm) Crankcase 35.4 69.4 103.4 Cylinder Head (Cap Screw) Crankcase…

• Page 6: Recommended Gasoline

  CAUTION tank is filled with cold gasoline and then moved to a Do not use white gas. Only Arctic Cat approved gaso- warm area. line additives should be used. ! WARNING…

• Page 7: Preparation After Storage

  Start the engine and allow will assure many miles and hours of trouble-free riding. it to idle; then using Arctic Cat Engine Storage Arctic Cat recommends the following procedure to pre- Preserver, rapidly inject the preserver into the air pare the ATV.

• Page 8: Periodic Maintenance

  * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

• Page 9: Lubrication Points

   NOTE: Foam Air Filter Cleaner and Foam Air Filter lowing procedure. Oil are available from Arctic Cat. 1. Remove the timing inspection plug; then remove the tappet covers and spark plugs (for more detailed 5. Squeeze the element by pressing it between the information, see Engine/Transmission — Servicing palms of both hands to remove excess solvent.

• Page 10: Valve Adjuster Procedure

  GZ063 GZ059  NOTE: At this point, the rocker arms and adjuster Valve Adjuster Procedure screws must not have pressure on them.  NOTE: The seat, storage compartment cover Feeler Gauge Procedure assembly, compartment box, air filter/filter housing, and left-side/right-side splash panels must be A.

• Page 11: Testing Engine Compression

  Testing Engine Spark Plugs Compression A light brown insulator indicates that a plug is correct. A white or dark insulator indicates that the engine may need To test engine compression, use the following procedure. to be serviced. To maintain a hot, strong spark, keep the plug free of carbon.

• Page 12: Engine/Transmission Oil — Filter

  1. Remove the three cap screws securing the spark arrester assembly to the muffler; then loosen and remove the arrester. H2-037A 3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan. CF105A 2.

• Page 13: Liquid Cooling System

   daily for leakage and damage. If leakage or damage is NOTE: Use a good quality, biodegradable gly- detected, take the ATV to an authorized Arctic Cat ATV col-based, automotive-type antifreeze. dealer for service. Also, the coolant level should be checked periodically.

• Page 14: Front Differential/Rear Drive Lubricant

  Front Differential/Rear Drive Lubricant  NOTE: The rear drive incorporates a shock-limiting clutch pack in the gear case input assembly that is designed to cushion driveline shock. CAUTION Any lubricant used in place of the recommended gear lube could result in premature failure of the shock lim- 737-651B iter.

• Page 15
  2. Connect the new bulb assembly to the wiring harness connector; then insert into the headlight housing and rotate fully clockwise. To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing. ATV-0070C …

• Page 16: Shift Lever

  4. Install the left-side engine cover and seat making sure the seat locks securely in place. Shift Lever  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 connectors, CHECKING ADJUSTMENT gear position switch connector, gear position switch, and LCD connector.

• Page 17
  B. Slowly compress the brake lever several times. C. Remove the protective cap, install one end of a clear hose onto the rear bleeder screw, and direct C. Remove the protective cap, install one end of a the other end into a container; then while holding clear hose onto the REAR RIGHT bleeder screw, slight pressure on the brake pedal, open the and direct the other end into a container;…

• Page 18: Burnishing Brake Pads

  CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thick- ness of each of the brake pads as follows. …

• Page 19
  CD078 GZ076 3. Remove the nut securing the movable drive face; then remove the face. Account for the flat washer and spacer.  NOTE: Keep the drive face plate in contact with the drive face when removing or installing the drive face to prevent the rollers from falling out.
• Page 20
  4. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws mak- ing sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to 8 ft-lb. GZ485A  NOTE: At this point, the cap screw in the fixed face can be removed.

• Page 21: Steering/Frame/Controls

  Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.

• Page 22
  FI463A FI470A 7. Remove the left and right footwells; then remove the shift knob. Remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. FI464A 5. Remove the cap screws and lock nuts securing the front rack to the frame;…
• Page 23
  CD681 CD681 9. Rotate the handlebar to the full-left position; then lift 3. Make sure the rubber grommets and bushings are in and slide the panel to the rear and lift the rear up to place; then place the front rack into position and clear the handlebar.

• Page 24: Rear Body Panel/Rack

  Rear Body Panel/Rack REMOVING 1. Remove the cap screws and lock nuts securing the rear rack; then remove the rear rack. Account for the bushings. 2. Remove one shoulder screw and lock nut and three plastic rivets (on each side) securing the rear body panel to the footwells.

• Page 25: Lcd Gauge

  4. Inspect for missing decals. 1. Remove the two reinstallable rivets securing the instrument pod; then remove the ignition switch INSTALLING retaining ring. 1. Remove the gas tank cap and set the rear body panel 2. Remove the two nuts securing the mounting studs; in position;…

• Page 26
  6. Remove the four cap screws securing the handlebar caps and LCD gauge bracket to the steering post; then move the handlebar and gauge out of the way. Account for four handlebar caps. FI465A 3. Remove four reinstallable rivets securing the steer- ing post cover and remove the cover.
• Page 27
  EPS007A AL600D 12. Remove four cap screws securing the EPS housing to CLEANING AND INSPECTING the frame; then lift the assembly upward sufficiently to disengage the lower coupler and remove from the 1. Clean and inspect the pivot area for wear. Apply a left side.

• Page 28: Handlebar Grip

  4. Connect the 2-pin and 8-pin connectors to the EPS assembly. 5. Install the upper steering post support to the frame and secure with two cap screws. Tighten to 20 ft-lb. 6. Install the storage compartment, steering post and radiator access panels, and storage compartment cover;…

• Page 29: Throttle Control

  INSTALLING  NOTE: Before installing a grip, use contact removal spray or alcohol to clean the handlebar of glue resi- due, oil, or any other contaminant. 1. Apply a liberal amount of Handlebar Grip Adhesive to the inside of a new grip. 2.

• Page 30: Steering Knuckles

  CAUTION Steering Knuckles Use extreme care when removing the bearing. If the bearing is allowed to fall, it will be damaged and will have to be replaced. REMOVING AND DISASSEMBLING CLEANING AND INSPECTING 1. Secure the ATV on a support stand to elevate the 1.

• Page 31
  NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (with- PR257 out an operator but with Arctic Cat approved acces- 7. Secure the brake caliper to the knuckle with new “patch-lock” cap screws. Tighten to 20 ft-lb.
• Page 32
  DE047A AF786D 5. Adjust the handlebar direction until the two measure-  NOTE: The distances from the inside rims to the ments are equal; then secure the handlebar to the rear frame tubes should be equal. If the measurements rack using tie-down straps. are equal, proceed to step 8;…

• Page 33: Front Rack

  INSTALLING 1. Place the spring into position between the upper shift 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. 2. Place the shift rod into position on the shift lever and secure with the existing E-clip.

• Page 34: Exhaust System

  2. Install the two flange bolts and lock nuts on the upper supports. Tighten all hardware securely. Exhaust System Footrests REMOVING MUFFLER 1. Remove the two exhaust springs at the muf- REMOVING fler/exhaust pipe juncture. 1. Remove the machine screws and flange nuts secur- ing the front and rear fenders to the footwells.

• Page 35: Seat

  2. Inspect all wires for corroding, pinching, and crack- ing. Seat 3. Inspect the bulb for wattage, voltage, and proper operation. INSTALLING REMOVING/INSTALLING 1. Place the assembly into position on the frame and 1. To remove the seat, lift up on the latch release secure with torx-head cap screws and any washers.

• Page 36: Specifications

  Valve Guide Inside Diameter 5.000-5.012 mm from the frame. Valve Stem Outside Diameter 4.972-4.987 mm  NOTE: Arctic Cat recommends the use of new gas- Valve Stem Runout (max) 0.1 mm kets, lock nuts, and seals and lubricating all internal Valve Head Thickness (min) 2.3 mm…

• Page 37: Troubleshooting

  Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Repair — replace guides 3. Valve timing incorrect 3. Replace cam chain/sprocket and retime engine 4.

• Page 38
  Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive — driven bevel gears damaged — worn 1. Replace gears 2. Backlash incorrect 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

• Page 39: Removing Engine/Transmission

  Removing Engine/Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service front Top-Side GZ091A Components, Left-Side Components, or Right-Side 4.

• Page 40
  GZ090B GZ368A 7. Disconnect the fuel injector wiring connectors; then 9. Loosen the clamps securing the V-belt cooling ducts remove the intake manifolds leaving the injectors to the V-belt housing; then disconnect the cooling installed. ducts. GZ106 GZ037 GZ107 GZ103B 8.
• Page 41
  GZ374 GZ071A 12. Remove the exhaust pipe springs at the muffler and 15. Remove the cap screw securing the engine and har- remove the muffler. Account for the grafoil seal. ness grounds to the engine. GZ372 GZ064A 13. Remove the nuts securing the rear exhaust pipe to the 16.
• Page 42
  GZ086A GZ369A 18. Remove the bleed screw from the water pump; then after coolant has drained, apply compressed air to the bleed opening to purge the remaining coolant from the system. Install the bleed screw and radiator drain plug and tighten securely. GZ008 20.

• Page 43: Servicing Engine

  21. Rotate the front driveshaft until the output yoke uni- Installing Left-Side Components ……….62 Right-Side Components…………65 versal joint is in the vertical plane; then raise the Removing Right-Side Components……….65 front of the engine/transmission until the front drive Servicing Right-Side Components………..67 splines disengage from the differential.

• Page 44
  GZ026 GZ126A 4. Remove all cap screws except the two top-side cap  NOTE: Timing marks on the rotor/flywheel are screws next to the spark plug. These will keep the stamped with an “F” (front cylinder) and “R” (rear cyl- alignment pins in place.
• Page 45
  GZ405 CC266D 7. Using an awl, rotate the C-ring in its groove until it is  NOTE: Loop the chain over the cylinder head and out of the cylinder head; then remove the C-ring. secure it to keep it from falling into the crankcase. …
• Page 46
  14. Remove the two nuts securing the cylinder to the crankcase. GZ151 GZ141A GZ161 12. If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the second GZ160A cylinder to top-dead-center of the compression stroke; 15.
• Page 47
  AT THIS POINT  Servicing Top-Side To service cylinder, see Servicing Top-Side Compo- Components nents sub-section. CAUTION VALVE ASSEMBLY When removing the cylinder, be sure to support the pis- ton to prevent damage to the crankcase and piston. When servicing valve assembly, inspect valve seats, valve 16.
• Page 48
  Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. CC132D 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ATV-1004 2. Acceptable widths must be within specifications. Measuring Valve Face Radial Runout 1.
• Page 49
  Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. CAUTION ATV-1011A 4. Place a spring retainer over the valve springs; then…
• Page 50
  Cleaning/Inspecting Piston 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves.
• Page 51
  CAUTION Incorrect installation of the piston rings will result in engine damage. CYLINDER /CYLINDER HEAD ASSEMBLY  NOTE: If the cylinder/cylinder head cannot be trued, they must be replaced as an assembly. Cleaning/Inspecting Cylinder Head CAUTION GZ168 The cylinder head studs must be removed for this pro- cedure.
• Page 52
   2. Inspect the cylinder for pitting, scoring, scuffing, NOTE: To produce the proper 60° cross-hatch pat- warpage, and corrosion. If marks are found, repair the tern, use a low RPM drill (600 RPM) at the rate of 30 surface using a cylinder hone (see Inspecting Cylinder strokes per minute.
• Page 53
  ATV1013A CC145D 2. The lobe heights must be greater than minimum 6. If clearance is excessive, measure the journals of the specifications. camshaft. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.
• Page 54
  CF060A GZ159 2. If damaged, the camshaft must be replaced. 3. Lubricate the inside wall of the cylinder; then using a ring compressor, compress the rings and slide the cyl- inder over the piston. Route the cam chain up through the cylinder cam chain housing;…
• Page 55
  GZ160A GZ132B 5. Install the coolant hose onto the crankcase union and 9. Loosely install the five cylinder head nuts. tighten the clamp. 10. In a crisscross pattern, tighten the four cylinder head C. Cylinder Head cap screws (from step initially to 20 ft-lb; then D.
• Page 56
  B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. CAUTION If any of the above factors are not as stated, go back to step 11 and carefully proceed.
• Page 57
  GZ193 GZ130 18. Rotate the crankshaft until the first cap screw (from  NOTE: At this point, oil the camshaft bearings, cam step 16) can be tightened; then tighten to 11 ft-lb. lobes, and the three seating journals on the cylinder. Bend the tab to secure the cap screw.
• Page 58
  GZ190B GZ195 A. Piston still at top-dead-center. 25. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install B. Camshaft lobes directed down (toward the piston). the cap screw (threads coated with red Loctite #271) and tighten to 11 ft-lb.
• Page 59
  27. Place the C-rings into position in their grooves in the cylinder heads. CD469 31. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until the CC012D tensioner spring bears tension; then install the cap 28. Install the cylinder head plugs in the cylinder heads with screw into the end of the chain tensioner.
• Page 60
  33. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder heads. GZ208 39. If removed, install the spark plugs. Tighten securely. GZ202 34. Lubricate the camshaft journals and lobes with engine Left-Side Components oil; then place the valve cover into position. …
• Page 61
  AT THIS POINT  To replace stator coils/crankshaft position sensor, see Electrical System. 2. Remove the starter motor, starter driven gear (A), starter countershaft bushing (B), and starter counter- shaft gear (C); then remove the starter gear shafts (D) noting the longer shaft is nearest the starter. GZ217 5.
• Page 62
  7. Remove the two cap screws securing the water pump to the crankcase. H2-022A 12. Remove the snap ring securing the speed sensor trig- ger to the shaft and remove the trigger using a suitable GZ230A “two-jawed” puller. Account for a gasket. 8.
• Page 63
  2. Inspect the starter clutch gear for chipped or missing teeth or discoloration/scoring of the clutch surface. Inspect the bearing for loose, worn, or discolored roll- ers. If bearing is damaged, it must be replaced. FI576A FI569 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration.
• Page 64
  3. Install the new stator coil assembly and secure with three cap screws using a drop of red Loctite #271 on each. Tighten according to the chart. Cover Bolt Type ft-lb Original Hex-Head Hex-Head 4. Place the stator wire harness hold-down into position; then install the crankshaft position sensor and secure with two cap screws.
• Page 65
  H2-019 H2-023 6. Install the shift cam plate onto the shift cam shaft and secure with the cap screw. Tighten to 8 ft-lb. GZ254 4. If removed, install the shim (E) and cam stopper (F); then H2-022A with the cam stopper support (B) in place, install the 7.
• Page 66
  8. Apply grease to the lips of the shift shaft seal in the gear shift cover; then using a new gasket, install the gear shift cover and secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. GZ226 12.
• Page 67
  Removing Right-Side Components A. CVT Cover B. Driven Clutch C. Clutch Cover D. Centrifugal Clutch 1. Remove the cap screws securing the CVT cover; then using a rubber mallet, gently tap on the cover tabs to loosen the GZ251 cover. Account for a gasket and two alignment pins. 15.
• Page 68
  PR388 GZ511 5. Remove the fixed drive face. 6. Remove the cap screws securing the V-belt housing to the crankcase; then remove the V-belt housing. Account for two alignment pins. CC596 9. Remove and retain the two machine screws and bear- ing retainers.

• Page 69: Driven Clutch Assembly

  11. Carefully remove the existing clutch housing seal using caution not to damage the sealing surface of the cover. GZ437A 16. Remove the water pump drive shaft and gear assem- bly from the engine. GZ513 12. Remove the one-way clutch from the centrifugal clutch.

• Page 70
  GZ442 GZ441 2. Remove the snap ring securing the bearing in the 2. Install the gear onto the driveshaft noting correct ori- water pump drive cover; then remove the bearing entation (from step 1 of disassembling). using an appropriate blind bearing remover. GZ442 3.
• Page 71
  GZ240 GZ503 2. Install the clutch shoe assembly and secure with the 5. Using a suitable press, install the bearing into the flange nut (threads coated with red Loctite #271). clutch cover against the outer bearing face. Tighten to 221 ft-lb. GZ501 GZ241 …
• Page 72
  GZ512 GZ263B 8. Install a new O-ring into a new fixed drive spacer, then apply a thin coat of grease to the inner O-ring and outside sealing surface of the drive spacer. Place it over the clutch housing assembly. GZ244A 11.
• Page 73
  GZ065A GZ485 14. Place the V-belt into position on the driven clutch and  NOTE: At this point, the cap screw can be removed over the front shaft. from between the driven clutch faces. 16. With the engine in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush with the top of the driven clutch.

• Page 74: Center Crankcase Components

  Center Crankcase Components  NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Remov- procedures Top-Side, Left-Side, Right-Side must precede this procedure.  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to H2-012B be addressed and to service only those components.

• Page 75
  GZ454A GZ298 2. Remove the snap ring securing the water pump drive idler (B) to the idler shaft; then remove the drive idler. GZ272B GZ299A Disassembling Crankcase 3. Remove the snap ring securing the water pump idler Half shaft (C) in the crankcase; then remove the shaft and bearings.
• Page 76
  7. Remove the driveshaft (G); then remove the counter- shaft assembly (with shift forks) (H). Account for two flat washers on the countershaft. GZ463B 5. Remove the shift fork shaft (E); then remove the gear shift shaft assembly (F). Account for a flat washer and a spacer.
• Page 77
  MT011A FW-003A 2. Using a suitable press, install the driven gear (C) on 4. Install a new seal (F), output yoke (G), washer, and the shaft until the gear firmly seats on the shoulder of nut (H) and tighten to 200 ft-lb. the shaft.
• Page 78
  Checking Backlash 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a 1. Install the drive bevel gear assembly and driven bevel thicker shim. gear/output shaft assembly into the crankcase bottom  cover. NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance.
• Page 79
  GZ357 GZ354A 3. Inspect the gerotor set for scoring, discoloration, or 6. Remove the oil seal from the oil pump cover. cracks; then using a feeler gauge, check the inner to outer rotor clearance. If measurements exceed specifi- cations, the gerotor set must be replaced. GZ365 Assembling GZ355…

• Page 80: Crankshaft Assembly

  CRANKSHAFT ASSEMBLY  NOTE: The crankshaft and connecting rod is a non-serviceable assembly. If any component is out of specification, the assembly must be replaced. Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore;…

• Page 81
  COUNTERSHAFT H2-004 3. Zero the indicator and rotate the crankshaft slowly. GZ281A CAUTION CAUTION Care should be taken to support the connecting rod When disassembling the countershaft, care must be when rotating the crankshaft. taken to note the direction each major component (dog, 4.
• Page 82
  GZ312 GZ319 3. Remove the reverse driven gear dog. GZ318A 6. Remove the low driven gear. Account for a bearing, GZ313A bushing, and thrust washer. 4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear. GZ316 Assembling GZ314…
• Page 83
  GZ318 GZ287 2. Install the low driven gear locking washer; then install 4. Install the outer reverse driven washer; then secure the the inner reverse driven gear washer. reverse driven gear assembly with a snap ring. GZ319B GZ288A GZ320B GZ314 3.
• Page 84
  GZ312 GZ347 6. From the opposite end of the countershaft, install the 3. Install the countershaft into the crankcase and secure high/low driven gear dog (A), thrust washer (B), bush- with the snap ring (flat side away from the bearing). ing (C), bearing (D), high/low driven gear (E), and spacer washer (F).
• Page 85
  GZ474 GZ335 9. Place the larger flat washer on the drive gear end of  NOTE: It will be necessary to rotate the crankshaft the countershaft and the smaller flat washer on the back and forth to engage the teeth of the oil pump high driven gear end;…

• Page 86: Joining Crankcase Halves

   NOTE: When applying silicone, make sure to keep clear of all oil galleys and ports. Do not over-apply silicone. GZ339 AT THIS POINT  Proper transmission shifting should be verified by turn- GZ345C ing the gear shift shaft to select High, Low, Neutral, and 4.

• Page 87
  Components, and to Installing Top-Side Components. Installing Engine/Transmission  NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. Turn the front driveline to place the output drive GZ452A yoke universal joint in the horizontal plane; then secure the driveshaft to the right and against the engine.
• Page 88
  GZ117A GZ064A 2. Install the engine/transmission into the frame from 8. Install the ignition coils and tighten the cap screws to the right side. 7 ft-lb; then connect the primary wires, grounds, and spark plug caps. 3. Rotate the driveshaft 90°; then lift the front of the engine sufficiently to engage the splined shaft into 9.
• Page 89
  GZ099A GZ090B 12. Connect the fuel injector, TPS connector (A), MAP sensor connector (B), and ISC valve connector (C). GZ372 11. Install the intake manifolds and tighten to 8 ft-lb; then install the throttle body and secure with the hose GZ094A clamps.
• Page 90
  16. Install the V-belt cooling duct and boots. Tighten securely. 17. Install the front body panel, footrests, foot wells, and front rack; then install the upper bumper sup- port-to-frame cap screws (see Steering/Frame/Con- trols). 18. Connect the negative battery cable; then secure the battery with the tool tray and install the seat.

• Page 91: Electronic Fuel Injection

   prevent inadvertent activation of the electronic fuel NOTE: Arctic Cat recommends the use of new gas- pump. kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.

• Page 92: Throttle Cable Free-Play

  GZ381A GZ094B 5. Remove the throttle arm cover and disconnect the throttle cable; then remove the throttle body from the ATV. GZ091A 3. Connect the wiring connector to the IAT sensor. 4. Install the front rack and body panel (see Steer- GZ383A ing/Frame/Controls).

• Page 93: Gas Tank

  4. Fill the gas tank with gasoline. Gas Tank 5. Start the engine and inspect for leakage. 6. Install the rear fenders and rack (see Steer- ing/Frame/Controls); then install the seat making sure it latches securely. ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, Oil Filter/Oil Pump there should be no welding, smoking, open flames, etc.,…

• Page 94: Oil Cooler

  2. Place the radiator with grommets and collars into When filling the cooling system, use premixed Arctic Cat position on the frame; then install the cap screws and Antifreeze. While the cooling system is being filled, air nuts.

• Page 95: Cooling Fan

  C. The thermostat should start to open at 71-86° C (160-187° F). D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear.  NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles.

• Page 96: Electric Fuel Pump/Fuel Level Sensor

  2. Remove the coolant hoses from the water pump; then 4. Install and tighten the coolant drain plug securely; remove two cap screws securing the water pump to then fill the cooling system with the proper amount the crankcase. of recommended coolant and install the radiator cap. 5.

• Page 97
  4. If the pump is not running, disconnect the fuel pump/tank sensor connector by reaching under the rear rack from behind. 5. Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire;…

• Page 98: Troubleshooting

   NOTE: It is important to install the fuel pump with the correct orientation to ensure adequate float lever clearance. 4. Connect the wires, fuel hose, and spring clamp; then turn the ignition switch to the ON position. Note that the fuel pump runs momentarily and the fuel gauge indicates the proper fuel level.

• Page 99: Electrical System

   NOTE: Optional battery charging adapters are avail- able from your authorized Arctic Cat dealer to con- nect directly to your vehicle from the recommended The electrical connections should be checked periodi- cally for proper function. In case of an electrical failure,…

• Page 100: Rpm Limiter

  Peak Voltage Reading Adapter must be used. If any other type of meter is used, readings may vary due to internal  NOTE: Arctic Cat recommends the use of the CTEK circuitry. When troubleshooting a specific component, Multi US 800 or the CTEK Multi US 3300 for battery always verify first that the fuse(s) are good, that the maintenance charging.

• Page 101: Brakelight Switch (Handlebar Control)

  VOLTAGE (Wiring Harness Side)  NOTE: The ignition switch must be in the ON position. 1. Set the meter selector to the DC Voltage position. VOLTAGE (Wiring Harness Connector) 2. Connect the red tester to the orange wire; then connect the black tester lead to the red/blue wire. 1.

• Page 102: Fan Motor

  Engine Coolant Temperature (ECT) Sensor 1. Connect the meter leads (selector in OHMS posi- tion) to the sensor terminals. 2. Suspend the sensor and a thermometer in a con- tainer of cooking oil; then heat the oil.  FI501A NOTE: Neither the sensor nor the thermometer 3.

• Page 103: Ignition Coil

  FUSES Primary Winding  NOTE: To remove a fuse, compress the locking tabs 1. Connect the red tester lead to either terminal; then connect the black tester lead to the other terminal. on either side of the fuse case and lift out. 2.

• Page 104: Speed Sensor

  6. On the sensor when the temperature reaches 110° C (230° F), the meter should read approximately EFI Sensors/Components 142 ohms. 7. If the readings are not as indicated, the sensor must be replaced. CRANKSHAFT POSITION (CKP) SENSOR To test the CKP sensor, see Stator Coil/Crankshaft Posi- Speed Sensor tion (CKP) Sensor in this section.

• Page 105: Electronic Power Steering (Eps)

  The EPS system is battery-system powered; therefore, the battery must be in good condition and fully charged. Power delivery and overload protection are provided by an EPS relay and 30-amp fuse, located under the seat in the Power Distribution Module (PDM). If a system malfunction occurs, a malfunction code “P0635”…

• Page 106
  Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1315 Engine RPM Faulty Engine RPM CAN signal received by Broken main harness CAN wires or EPS will auto-recover when engine the EPS incorrect or missing defective ECM. RPM signal returns to normal C1316 EEPROM Error EPS internal memory error has been Internal EPS condition…

• Page 107: Ignition Switch

   NOTE: Prior to troubleshooting below, make sure B. Check the AC generator using the Stator Coil/Crankshaft Position (CKP) Sensor procedure that Ignition Key Switch has not been left on with the found in this section. If not to specifications, engine not started.

• Page 108: Handlebar Control Switches

   NOTE: If the meter shows more than 1 ohm of resis- tance, replace the switch. RESISTANCE (LO Beam) 1. Connect the red tester lead to the white wire; then connect the black tester lead to the gray wire. 2. With the dimmer switch in the LO position, the meter must show an open circuit.

• Page 109: Drive Select Switch

  2. Connect the red tester lead to one red/yellow wire; then connect the black tester wire to the other red/yel- Front Drive/Differential low wire. The meter must show less than 1 ohm. Lock Actuator 3. Depress and hold the reverse override button. The meter must show an open circuit.

• Page 110: Starter Relay

  RESISTANCE (AC Generator) Stator Coil/Crankshaft 1. Set the meter selector to OHMS position. Position (CKP) Sensor 2. Test between the three yellow wires. 3. The meter reading must be within specification. VOLTAGE RESISTANCE (AC Generator — Regulated Output) (Crankshaft Position Sensor) 1.

• Page 111: Starter Motor

  3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts and a “click” should be heard from the relay.  NOTE: If a “click” is heard and more than 1 volt is indicated by the multimeter, replace the starter relay. If no “click”…

• Page 112: Ignition Timing

   The ECM is rarely the cause for electrical problems; how- NOTE: If battery voltage is not shown in any test, ever, if the ECM is suspected, substitute another ECM of the inspect the LIGHTS fuse, battery, main wiring har- same part number to verify the suspected one is defective.

• Page 113: Tilt Sensor

  If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil/CKP sensor bracket may be bent or damaged, or the ECM may be faulty. Tilt Sensor ! WARNING Incorrect installation of the tilt sensor could cause sud- den loss of engine power which could result in loss of vehicle control resulting in injury or death.

• Page 114: Efi Diagnostic System

   4. Tilt the sensor 60° or more to the left and right NOTE: Prior to testing the TPS, inspect the observing the meter. The meter should read three-wire plug connector on the main harness and 3.0-7.0 DC volts after approximately one second the three-pin plug on the TPS for contamination, bro- in the tilted position.

• Page 115
  1. Make sure the ignition switch is in the OFF posi- • 16 = Speed Sensor tion; then remove the seat. • 21 = IAT (Inlet Air Temperature) Sensor • 23 = Tilt Sensor* 2. Locate the diagnostic plug next to the PDM; then •…

• Page 116: Troubleshooting

  Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace stator coil 4. ECM defective 4. Replace ECM 5. Pick-up coil defective 5.

• Page 117
  Problem: Battery discharges too rapidly Condition Remedy 1. Charging system not charging 1. Check magneto — regulator/rectifier — circuit connections 2. Cell plates overcharged — damaged 2. Replace battery — correct charging system 3. Battery short-circuited 3. Replace battery 4. Electrolyte contaminated 4.

• Page 118: Drive System/Brake System

  REMOVING Drive System/Brake 1. Disconnect the connector on the actuator harness. System 2. Using a T-30 torx wrench, remove the mounting cap screw from the driveshaft side of the actuator.  NOTE: Specifications regarding the gear cases (capacities, lubricant type, etc.) can be found in Gen- eral Information of this manual.

• Page 119: Front Differential

  1. Lubricate the O-rings on the actuator; then ensure 6. Turn the ignition switch to the ON position and that all mounting surfaces are clean and free of check the operation by shifting the drive select debris. switch several times. 2.

• Page 120
   NOTE: It is not necessary to remove the brake hoses from the calipers for this procedure. 7. Remove the two brake calipers. Account for the four cap screws. AF628D 11. Pull the steering knuckle away from the axle. AF894D …
• Page 121
  AF610D CD026 15. Push the axle shaft firmly toward the differential to 19. Remove the upper differential mounting cap screws. release the internal lock; then while holding the axle in, pull the CV cup from the differential.  NOTE: Keeping the axle level will aid in removal. CAUTION Do not attempt to use a slide hammer or damage will occur.
• Page 122
  KX159 CD106 3. Using a boot-clamp pliers (or suitable substitute), Disassembling Input Shaft remove the boot clamps; then remove the boots and splined drive from the input shaft.  NOTE: This procedure can be performed on a rear gear case; however, some components may vary 4.
• Page 123
  GC011 GC011 2. Install the input shaft seal making sure it is fully seated in the housing. AF984 GC014 3. Lubricate the input shaft with High-Performance #2 Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess grease to freely escape.
• Page 124
  CD112 GC015 2. Using a T-40 torx wrench, remove the cap screws securing the differential cover. Account for and make note of the ID tag location for assembling purposes. CD099 5. Place the pinion housing with new gasket onto the gear case housing;…
• Page 125
  KX175 KX181 5. Remove the left differential bearing flange assembly Disassembling Pinion Gear and account for a shim. Mark the shim as left-side. 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
• Page 126
  CC879 CC884 4. Remove any reusable parts from the gear case hous- 3. Using a propane torch, heat the gear case housing to ing; then discard the housing and lock collar. approximately 200° F; then install the pinion assem- bly. Assembling Pinion Gear 4.
• Page 127
   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 0.051-0.055-in. shim on the gear case side of the ring gear assembly.
• Page 128
  2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.  NOTE: Once proper backlash and end play are established, the gear case can be assembled.
• Page 129
  GC036B CF275A  5. Making sure the O-ring is properly positioned on the NOTE: The spider and ring gear assembly must be differential housing cover assembly, install the cover replaced as a complete unit. with existing cap screws (coated with green Loctite #609).
• Page 130
   NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb. CF278 CAUTION Make sure the tool is free of nicks or sharp edges or CD103 damage to the seal may occur. 3. Repeat steps 1-2 for the opposite side. INSTALLING DIFFERENTIAL 1.

• Page 131: Drive Axles

  AG925 AF896D 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this sec- tion). 6. Secure the upper A-arms with cap screws and lock nuts. Tighten to 50 ft-lb. AF895D 9. Install the brake calipers and secure with new “patch-lock”…

• Page 132
  2. Pump up the hand brake; then engage the brake lever lock. 3. Remove the wheel. 4. Remove and discard the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock. PR729C REMOVING FRONT DRIVE AXLE …
• Page 133
  CF337 ATV-1048 2. Place the white-striped end of the CV joint into a 3. Apply 80 grams (2/3 of contents) of grease from the vise. pack into the bearing housing.  NOTE: Steps 1-3 can be used to replace the out- board boot.

• Page 134: Rear Gear Case

  7. Install the wheel and tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 8. Remove the ATV from the support stand and release the brake lever lock. 9. Check the front differential oil level and add oil as necessary.

• Page 135
  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. AF960A AT THIS POINT  For servicing the input shaft, pinion gear, needle bear- ing, ring gear, and axle seal, see Front Differential in GC058A this section.
• Page 136
  GZ392 GZ182A 4. Remove the snap ring retaining the input bearing and using an appropriate bearing driver, press the bearing from the housing. GZ176A GZ184A Cleaning and Inspecting 1. Wash all parts in parts-cleaning solvent and dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air.
• Page 137
   NOTE: The clutch pack is not a serviceable compo- nent. If worn, discolored, or damaged in any way, it must be replaced. Assembling/Installing 1. Install a new bearing into the input housing and secure with the snap ring (flat side directed away from bearing).

• Page 138: Cylinder Assembly

  PR243A PR243A 6. Using an appropriate hub retaining wrench, tighten  NOTE: Do not allow the brake calipers to hang from the hex nut (from step 4) to 200 ft-lb; then install and their cable/hose. spread a new cotter pin making sure each side of the pin is flush to the hex nut.

• Page 139
  AF637D DE058A 2. Place an absorbent towel around the connection to INSPECTING absorb brake fluid. Remove the banjo-fitting from the master cylinder. Account for two crush washers 1. Inspect the pin securing the brake lever for wear. and a banjo-fitting bolt. 2.

• Page 140: Hydraulic Brake Caliper

  Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.

• Page 141
  PR238 PR715 5. Remove the caliper holder from the caliper and dis- ! WARNING card the O-ring. Make sure to hold the towel firmly in place or the piston could be ejected from the housing causing injury. 7. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing;…
• Page 142
  PR719C PR715 4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented.  NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR717A 2. Press the piston into the caliper housing using hand pressure only.

• Page 143: Troubleshooting Drive System

  7. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb. 8. Fill the reservoir; then bleed the brake system (see Periodic Maintenance). ! WARNING Never use brake fluid from an open container or reuse brake fluid.

• Page 144: Shock Absorbers

  Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. AF605D D.

• Page 145: Front A-Arms

  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 (where appropriate) into shock eyelet;…

• Page 146
  10. Remove the cap screws securing the A-arms to the frame. AF616D 2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten AF610D at this time. 11. Remove the circlip from the ball joint; then remove the ball joint from the A-arm.

• Page 147: Rear A-Arms

  AF628D CD007 7. Install the tie rod end and secure with the nut. 11. Using an appropriate hub retaining wrench, secure Tighten to 30 ft-lb; then install a new cotter pin and the hub nut (from step 9) to the shaft/axle. Tighten to spread the pin to secure the nut.

• Page 148
   NOTE: Do not allow the brake caliper to hang from the cable/hose. 6. Remove the cap screws and lock nut securing the shock absorber to the frame and lower A-arm; then remove the shock absorber. 7. Remove the cap screws securing the boot guard to the lower A-arm.

• Page 149: Wheels And Tires

  TIRE SIZE of rotation). ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed in General Information. Do not under any circumstances substitute tires of a different type or size.

• Page 150: Troubleshooting

  Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber 3. Shock absorber preload too low 3. Adjust shock absorber preload Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1.

• Page 151
  Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-849…

Arctic Cat ATVs have long been a success with amateurs and professionals due to their brilliant technical characteristics, excellent design and most importantly — the highest
reliability.

The company’s products have earned the status of all-terrain vehicles for excellent cross-country ability even in the most adverse terrain, and achieved without compromising maneuverability and
other properties.

The company Arctic Cat (USA) began operations for more than half a century ago — in 1960.

Such a long presence in the global market helps to maintain a leading position.

Constantly developing production, improving snowmobiles and ATVs, releasing new, all the best models and adhering to a winning pricing policy.

The main advantages (advantages) of the Arctic Cat ATVs:

• lowered center of gravity, providing all-terrain and preventing overturning;
• high ground clearance;
• independent suspension;
• low fuel consumption;
• Great ergonomics combined with great design.

By the way, the reliable partner powerful motor vehicles Arctic Cat supplies the famous partner — the Japanese brand Suzuki.

ATVs of this company are bought even by the Pentagon — for use in the US Army. They are also supplied to the Finnish border agency to patrol the border with Russia.