Arctic Cat 2015 400 Service Manual
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Arctic Cat 2015 400 Service Manual

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S E R V I C E M A N U A L
400
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  • Page 1 S E R V I C E M A N U A L www.arcticcat.com...
  • Page 2 This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The proce- dures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information............2 Servicing Right-Side Components ........56 Installing Right-Side Components.........57 General Specifications............2 Center Crankcase Components..........60 Torque Specifications ............. 3 Separating Crankcase Halves..........60 Torque Conversions (ft-lb/N-m)..........4 Gasoline - Oil - Lubricant............4 Disassembling Crankcase Half ..........61 Servicing Center Crankcase Components ......62 Genuine Parts.................

  • Page 4: General Information

    0.10 mm Gasoline (recommended) 87 Octane Regular Unleaded Clearance (max) (exhaust) 0.30 mm Engine Oil (recommended) Arctic Cat ACX All Weather Valve Guide Inside Diameter 5.000-5.012 mm (Synthetic) Valve Head Thickness (min) 2.30 mm Differential/Rear Drive Lubricant SAE Approved 80W-90 Hyp- Valve Seat Angle (intake/exhaust) 45°...

  • Page 5: Torque Specifications

    DRIVE TRAIN COMPONENTS Torque Specifications Torque Part Part Bolted To ft-lb N-m Engine Mounting Through-Bolt Frame Front Differential Frame/Differential Bracket EXHAUST COMPONENTS Output Flange Rear Output Flange Joint Torque Part Part Bolted To Input Shaft Housing Differential Housing ft-lb N-m Pinion Housing Gear Case Housing Exhaust Pipe...

  • Page 6: Torque Conversions (Ft-Lb/N-M)

    35.4 69.4 103.4 tor-based oils. 36.7 70.7 104.7 The recommended oil to use is Arctic Cat ACX All 38.1 72.1 106.1 Weather synthetic engine oil, which has been specifically 39.4 73.4 107.4 formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the 40.8...

  • Page 7: Genuine Parts

    When replacement of parts is necessary, use only genuine Taking the ATV out of storage and correctly preparing it Arctic Cat ATV parts. They are precision-made to ensure will assure many miles and hours of trouble-free riding. high quality and correct fit. Refer to the Illustrated Parts...

  • Page 8: Periodic Maintenance

    Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 9: Valve/Tappet Clearance

    5. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element. Insert the form- ing spring into the element with the closely wrapped end of the spring toward the open end of the element. CAUTION A torn air filter element can cause damage to the ATV engine.

  • Page 10: Testing Engine Compression

    Feeler Gauge Procedure Using a feeler gauge, check each valve/tappet clearance. Testing Engine If clearance is not within specifications, loosen the jam Compression nut and rotate the tappet adjuster screw until the clear- ance is within specifications. Tighten each jam nut securely after completing the adjustment.

  • Page 11: Muffler/Spark Arrester

    ATV-0051 KC334A 2. Using a suitable brush, clean the carbon deposits CAUTION from the screen taking care not to damage the screen. Before removing a spark plug, be sure to clean the area  NOTE: If the screen or gasket is damaged in any around the spark plug.

  • Page 12: Adjusting Engine Rpm (Idle)

    2. Remove the seat and left-side engine cover. 3. Remove the oil level stick/filler plug. ATV-0047 3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. KC0051A 4. Remove the drain plug from the bottom of the engine Adjusting Engine RPM and drain the oil into a drain pan.

  • Page 13: Front Differential/Rear Drive Lubricant

    11. Remove the oil level stick and wipe it with a clean 2. Drain the lubricant into a drain pan by removing the cloth; then install the oil level stick into engine case. drain plug from each.  NOTE: The oil level stick should be threaded into the case for checking purposes.

  • Page 14: Driveshaft/Coupling

    TIRE INFLATION PRESSURE With the engine stopped and the brake lever lock engaged, turn the ignition switch to the ON position; then Front and rear tire inflation pressure should be 27.6 kPa shift the transmission into each of the gear positions and (4.0 psi).

  • Page 15: Hydraulic Brake Systems

    Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake sys- tem, use the following procedure. 1. With the master cylinder in a level position, check the fluid level in the reservoir.

  • Page 16: 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. 1.
  • Page 17 4. Thread a cap screw from the V-belt cover into the driven pulley fixed face and push the movable face open allowing the V-belt to drop down between the pulley faces approximately 3/4 in. KC149A 2. Slide the auxiliary brake pedal part way off the pivot stud but do not remove;...
  • Page 18 KC131 KC141 2. Install the bushing over the clutch shaft; then install 4. Remove the cap screw from the fixed driven face; the movable drive face assembly on the clutch shaft. then rotate the pulleys counterclockwise until the driven pulley faces are together. 5.

  • Page 19: Steering/Frame/Controls

    3. Remove the cap screws (A); then remove the rein- stallable rivets (B) and remove the tank cover. 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.

  • Page 20: Rear Body Panel/Rack

    6. Remove the electric panel; then disconnect the LCD 3. Install the screws securing the front body to the front gauge connector, ignition switch, and accessory out- body supports; then install the left-side and right-side let. footwell fasteners. Do not tighten at this time. 4.
  • Page 21 CLEANING AND INSPECTING 1. Clean all rear body panel components with warm soap and water. 2. Inspect side panels and rear body panel for cracks and loose rivets. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals. INSTALLING 1.

  • Page 22: Steering Post/Tie Rods

    4. Remove the cotter pins from the inner tie rod ends; then remove the nuts and disconnect the inner tie rod ends. KC322 3. Secure the rear fenders to the footwells and tighten the nuts securely. 4. Install the side panels and seat. KC184A ...

  • Page 23: Lcd Gauge

    INSTALLING 1. Install the steering post into the frame and secure the lower end in the bearing with a flat washer and cap screw. Tighten to 40 ft-lb. KC0058 5. Install the steering post cover; then install the front body panel/fender. LCD Gauge KC184B 2.

  • Page 24: Handlebar Grip

    KC516B KC309A 3. Install the new gauge and mounting bracket; then 2. Grasp the end and remove the cap screw, plug, and connect the wiring harness to the gauge. end cap. 4. Put the instrument pod into position making sure the rear tab is in position first;...

  • Page 25: Steering Knuckles

    AF676D AF679D 3. Remove the cap screw, lock washer, and washer 2. Using a pair of needle-nose pliers, place the spring securing the actuator arm to the throttle control lever. into position on the actuator arm. AF677D AF680D 4. Remove the actuator arm and account for a bushing. 3.
  • Page 26 8. Tap the ball joint end out of the knuckle; then remove the knuckle. 9. Remove the snap ring from the knuckle; then remove the bearing. PR287A 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb.

  • Page 27: Measuring/Adjusting Toe-Out

     NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (with- 733-559A out an operator but with Arctic Cat approved acces- sories). Front Rack 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each side.

  • Page 28: Front Bumper Assembly

    INSPECTING MUFFLER 4. Inspect for missing decals and/or reflectors. INSTALLING 1. Inspect muffler externally for cracks, holes, and dents. 1. Place the rack into position on the frame and front fender panel. Install the cap screws and lock nuts and 2.
  • Page 29 KC146A KC163B 5. Connect the wiring harness connector to the bulb; then install the protective rubber boot making sure it seals completely on the headlight harness. KC162 2. Press in and release the spring retainer and pull rear- ward clear of the bulb assembly. KC146 TAILLIGHTS-BRAKELIGHTS To replace a taillight-brakelight bulb, use the following...
  • Page 30 1. Rotate the bulb socket counterclockwise to release from light housing; then press in on the bulb and turn counterclockwise to release from the socket. ATV-0070C  NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. KC158A 2.

  • Page 31: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate steering shaft 3. Tire inflation pressure low 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 32: Engine/Transmission

    Refer to the current Special Tools Catalog for the appro- engine/transmission does not have to be removed from priate tool description. the frame.  NOTE: Arctic Cat recommends the use of new gas- Description kets, lock nuts, and seals and lubricating all internal Crankcase Separator/Crankshaft Remover...

  • Page 33: 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. Replace cylinder head 3. Valve timing incorrect 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4.
  • Page 34 Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - chipped 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - chipped 3. Replace gears 4. Bearings worn 4. Replace bearings 5.
  • Page 35 Problem: Engine overheats Condition Remedy 1. Carbon deposit (piston crown) excessive 1. Clean piston 2. Oil low 2. Add oil 3. Octane low - gasoline poor 3. Drain - replace gasoline 4. Oil pump defective 4. Replace pump 5. Oil circuit obstructed 5.

  • Page 36: 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 Top-Side Com- KC250 ponents, Left-Side Components, or Right-Side Compo- nents, the engine/transmission does not have to be...
  • Page 37 KC235 KC228C KC236 KC228B 6. Remove the cap screws securing the exhaust pipe to 8. Remove the front and rear V-belt cooling boots from the cylinder head; then disconnect the exhaust pipe the V-belt housing. to muffler springs and remove the exhaust pipe. 9.

  • Page 38: Top-Side Components

    3. Remove the cam chain tensioner. Account for a gas- ket.  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- sion.
  • Page 39 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1245  NOTE: Remove the cam chain tensioner pivot cap screw and washer. MD1131  NOTE: Care should be taken not to drop the C-ring down into the crankcase.
  • Page 40 12. Lift the cylinder off the crankcase taking care not to 9. Remove the cylinder head from the cylinder, remove allow the piston to drop against the crankcase. the gasket, and account for two alignment pins. Account for the gasket and two alignment pins. MD1163 MD1214 AT THIS POINT...

  • Page 41: Servicing Top-Side Components

     NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a connect- ing rod holder. CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result.
  • Page 42 3. If a valve guide is out of tolerance, the cylinder head must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CC994 CAUTION PISTON ASSEMBLY If valves are discolored or pitted or if the seating sur- ...
  • Page 43 2. Inspect and measure the connecting rod small end. If the measurement exceeds specifications, the con- necting rod must be replaced (see Center Crankcase Components in this section). 3. Insert an inside dial indicator into the piston-pin bore. Take two measurements to ensure accuracy. The diameter must not exceed specifications.
  • Page 44 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 45 CC997 CC390D 4. If any measurement exceeds the limit, the cylinder Inspecting Cam Chain Guide must be replaced. 1. Inspect cam chain guide for cuts, tears, breaks, or Measuring Camshaft Runout chips.  NOTE: If the camshaft is out of tolerance, it must be 2.

  • Page 46: Installing Top-Side Components

    Inspecting Camshaft Bearing  NOTE: The piston should be installed so the arrow Journal points towards the exhaust. 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 47  NOTE: The two cylinder-to-crankcase nuts will be tightened in step 9. MD1347 KC337A C. Cylinder Head/Camshaft D. Cylinder Head Cover/Rocker Arms  NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder.
  • Page 48 9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to 28 ft-lb. Tighten the two lower cylinder head nuts (from step 8) to 20 ft-lb and the cylinder-to-crankcase nuts (from step 4) to 8 ft-lb.
  • Page 49 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down- CAUTION wards. Care must be taken that the tab washer is installed cor- 21. Remove the cap screw from the end of the chain ten- rectly to cover the alignment hole on the sprocket.

  • Page 50: Left-Side Components

    31. Install the spark plug and tighten securely; then install the timing inspection plug. Left-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
  • Page 51 CC946 MD1365 6. Using Magneto Rotor Remover, break the rotor/fly- wheel assembly loose from the crankshaft. Remove the remover, the crankshaft protector, the rotor/fly- wheel, and the starter clutch gear. Account for the key. CAUTION Care must be taken that the remover is fully threaded onto the rotor/flywheel or damage may occur.

  • Page 52: Servicing Left-Side Components

    KC217 12. Remove starter motor by tapping lightly with a mal- MD1370 7. Remove the starter idler gear (No. 1) and starter idler let. gear (No. 2).  NOTE: The starter motor is a non-serviceable com- ponent and must be replaced as an assembly. 13.
  • Page 53 FI569 FI576A 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING FI572 1. Support the starter clutch gear in a press making sure REPLACING STARTER CLUTCH to support the hub around the entire circumference;...

  • Page 54: Installing Left-Side Components

    FI580 MD1239 6. Install starter idler gear (No. 2) and starter idler gear (No. 1). Installing Left-Side Components A. Starter Idler Gears B. Rotor/Flywheel 1. Place the crankshaft bearing retainer into position. Apply red Loctite #271 to the three cap screws. Install and tighten the three cap screws securely.

  • Page 55: Removing Right-Side Components

    AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components MD1033...
  • Page 56 MD1118 MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of 6. Remove the fixed drive face. the different-lengthed cap screws for installing pur- poses. 10. Using a rubber mallet, loosen the clutch cover; then pull it away from the right-side crankcase half.
  • Page 57 KC326A MD1016 11. Remove the one-way clutch noting the direction of 13. Remove the cam chain. the green dot or the word OUTSIDE for installing purposes. MD1335 14. Remove the oil pump drive gear cap screw. MD1286 12. Remove the left-hand threaded nut holding the cen- trifugal clutch assembly.

  • Page 58: Servicing Right-Side Components

    Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. 2. Inspect the depth of the grooves in the clutch shoes. If any shoe is worn to the bottom of the groove, MD1019 replace the complete set.

  • Page 59: Installing Right-Side Components

     NOTE: It will be necessary to rotate the clutch hous- ing counterclockwise to properly seat the one-way clutch. MD1060 2. Place the thrust washer and drive pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring.
  • Page 60 MD1017 KC325A MD1018 KC326B 5. Install the clutch shoe assembly on the crankshaft; B. Clutch Cover then install the flange nut (left-hand thread) (coated C. Fixed Drive Face with red Loctite #271). Tighten to 147 ft-lb. D. Movable Drive Face ...
  • Page 61 11. Slide the fixed drive face assembly onto the front shaft. 12. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 MD1117 9.

  • Page 62: Center Crankcase Components

    Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. KC141  NOTE: At this point, the cap screw can be removed from the driven pulley face. 15.

  • Page 63: Disassembling Crankcase Half

    Disassembling Crankcase Half 1. Remove the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the driven gear. MD1327 5. Remove snap ring and gear from the output side of the gear cluster. Remove the gear cluster and the inner shift fork together.

  • Page 64: Servicing Center Crankcase Components

    1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft. 2. Install the secondary driven output shaft assembly onto the crankcase. 3. Mount the indicator tip of the dial indicator on the secondary driven bevel gear (centered on the gear tooth).
  • Page 65  NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted. CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the cor- recting backlash/correcting tooth contact procedures until they are both within tolerance values.
  • Page 66 CC289D KC513 3. Acceptable gap range must be within specifications. 2. Acceptable width range must be within specifica- tions. Measuring Connecting Rod COUNTERSHAFT (Big End Width) CAUTION 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. When disassembling the countershaft, care must be taken to note the direction each major component (dog, 2.
  • Page 67 FI665 FI669 3. Remove the low driven gear washer; then remove the 5. Remove the circlip securing the high driven gear; low driven gear along with the bearing and bushing. then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer.
  • Page 68 FI671A FI666 4. Place the reverse driven bushing (13) onto the shaft; then install the bearing (14), gear (15), and splined washer (16). Secure with a snap-ring. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7); then install the splined washer (8).

  • Page 69: Assembling Crankcase Half

    2. Apply red Loctite #271 to the threads of the output shaft. Install and tighten the nut 59 ft-lb. Using a punch, peen the nut. FI662  NOTE: The countershaft assembly is now ready to be installed. MD1333 3. Apply a liberal amount of oil to the crankshaft bear- ing.
  • Page 70 FI652A FI655A 7. Place the shift forks into position on the assembled 9. Install the input driveshaft. countershaft and install into the crankcase as an assembly. FI646 10. Install the spacer (1), shaft (2), reverse idler gear, and washer (3). FI662 FI653 FI641A...

  • Page 71: Joining Crankcase Halves

    11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses; then install the center carrier bearing alignment C-ring. MD1336 2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed.

  • Page 72: Installing Engine/Transmission

    6. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws to 10 ft-lb.  NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. AT THIS POINT  After completing center crankcase components, pro- ceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Com- ponents.
  • Page 73 7. Place the carburetor into the intake pipe being care- ful to align the lug on the carburetor with the align- ment tabs on the air intake pipe; then tighten the clamp securely. KC228B 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal.
  • Page 74 KC248 KC251 10. Connect the oil temperature connector and cooling 11. If the brake pedal was removed during disassem- fan connector; then using new O-rings, install the oil bling, apply grease to the brake pedal pivot stud; fittings onto the crankcase and secure with the cap then install the brake pedal and secure with a flat screws.

  • Page 75: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- sion. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 76: Carburetor

    3. Loosen the clamp on the intake pipe and lift the car- buretor up and to the rear; then disconnect the elec- Carburetor tric choke connector and vent hose. KC256A 1. Cover 15. Float Pin 27. Float Chamber Assy 2. Screw 16.
  • Page 77 DISASSEMBLING 1. Remove the four Phillips-head screws securing the top cover; then remove the cover. KC0022A KC0019A 2. Remove the vacuum piston assembly from the carbu- retor body. Account for a spring, spring seat, and the jet needle. KC0063A 5. Remove the float pin. KC0021A 3.
  • Page 78 CLEANING AND INSPECTING. ! WARNING When drying components with compressed air, always wear safety glasses. CAUTION DO NOT place any non-metallic components in parts-cleaning solvent because damage or deterioration will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner.
  • Page 79 KC0028A KC0031  NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the rec- ommended number of turns as an initial setting.  NOTE: Note the locations of the jets and holder dur- ing assembling procedures. KC0030A 5.
  • Page 80 KC0035 CC748 6. Place the float chamber into position making sure the CAUTION O-ring is properly positioned; then secure with the It is important to press down on the pump housing until Phillips-head screws. it contacts the carburetor to make sure the diaphragm lip is properly seated in the groove in the carburetor.

  • Page 81: Throttle Cable Free-Play

    3. Install the carburetor onto the engine making sure the alignment lug on the carburetor is between the two tabs on the air intake pipe; then tighten the clamp securely. KC264A KC245A KC263 2. Adjust the throttle cable free-play to specifications (see Periodic Maintenance - Adjusting Throttle Cable);...

  • Page 82: Gas Tank

    Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. REMOVING 1. Turn the fuel shut-off valve to the OFF position; then KC220 remove the seat and side panels.
  • Page 83 KC514A KC252A 8. Using a suitable block, support the rear of the tank; 2. Using a suitable block, support the rear of the tank then remove the clamp securing the gasline hose and and connect the gasline hose. Secure with the clamp.

  • Page 84: Oil Filter/Oil Pump

    KC219A KC267 6. Install the fuel shut-off valve knob; then turn the  NOTE: Some oil seepage may occur when installing valve to the ON position. the oil pressure gauge. Wipe up oil residue with a cloth. 7. Install the side panels and seat making sure they lock 3.

  • Page 85: Oil Cooler

    1. Remove the input and output hoses from the fittings on the cooler. Oil Cooler CAUTION Elevate and secure the hoses to avoid oil spillage. 2. Remove the cap screws securing the oil cooler to the frame. Account for grommets. 5.

  • Page 86: Electrical System

    Maintenance Charging Electrical System  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two This section has been organized into sub-sections which weeks or as required by battery drain.

  • Page 87: Rpm Limiter

    Charging 2. Connect the red tester lead to the red wire; then con-  NOTE: Arctic Cat recommends the use of the CTEK nect the black tester lead to ground. Multi US 800 or the CTEK Multi US 3300 for battery 3.

  • Page 88: Oil Temperature And Cooling Fan Switches

    RESISTANCE (Switch) 3. On the oil temperature switch when the oil tempera- ture reaches 160° C (320° F), the meter should read a 1. Remove the spade connectors from the brake switch. closed circuit. 2. Set the meter selector to the OHMS position. 4.

  • Page 89: Fuse Block/Power Distribution Module

    RESISTANCE (Fan Motor Connector) 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the red wire; then con- nect the black tester lead to the black wire. 3. The meter must show less than 1 ohm. ...

  • Page 90: Ignition Coil

     NOTE: The battery must be at full charge for these tests. Ignition Coil Primary/CDI  NOTE: The CDI is located on the electrical tray in The ignition coil is on the frame above the engine. To front of the steering shaft. access the coil, the left side panel must be removed.

  • Page 91: Ignition Switch

    KC248A KC339D 3. Turn the ignition switch to the ON position. VOLTAGE 4. The meter must show greater than 5.0 volts.  NOTE: Perform this test on the main harness con- 5. Leave the black tester lead connected; then connect nector.

  • Page 92: Handlebar Control Switches

    Handlebar Control Gear Position Switch Switches The gear position switch connector is located on the right side of the engine over the V-belt housing. The connectors are located on the right side of the ATV next to the PDM. To access the connector, the electrical cover must be removed.

  • Page 93: Starter Relay

    VOLTAGE (Charging Coil - No Load) 2. Connect the red tester lead to the positive battery ter- minal; then connect the black tester lead to the starter The connector is the black three-pin one on the right side cable connection on the starter relay. The meter must of the engine just above the starter motor.

  • Page 94: Cdi Unit

     NOTE: If the meter showed no voltage, inspect ground connections, starter motor lead, battery volt- Regulator/Rectifier age (at the battery), starter relay, or the neutral start relay. REMOVING The regulator/rectifier is located under the front rack and front fenders above the oil cooler. 1.
  • Page 95 3. The meter must show battery voltage.  NOTE: If the meter does not show voltage, inspect fuses, wiring harness, connectors, and switches. Voltage (Brakelights)  NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the ON position and the brake (either foot pedal or hand lever) must be applied.

  • Page 96: Ignition Timing

    3. Set the tester to DC VOLTS; then turn the ignition B. If the meter does not show battery voltage, inspect switch to the ON position and move the shift lever to the LIGHTS fuse, ignition switch, or the main the R (reverse) position.
  • Page 97 Problem: Alternator overcharges Condition Remedy 1. Battery shorted 1. Replace battery 2. Regulator/rectifier damaged - defective 2. Replace regulator/rectifier 3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection Problem: Charging unstable Condition Remedy 1. Stator wire intermittently shorting 1. Replace stator wire 2.

  • Page 98: Drive System

    3. Remove the front wheels. Drive System 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut. GENERAL INFORMATION 6. Release the brake lever lock. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play...
  • Page 99 KC425A CD102 2. Remove the cap screws securing the pinion housing;  NOTE: In some instances it may be necessary to then using a rubber mallet, remove the housing. use an appropriate axle puller to remove the axle Account for a gasket. Note the location of all the from the differential.
  • Page 100 AF983 AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulphide Grease.  NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air;...
  • Page 101  NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. CD112 5. Using a new O-ring lubricated with grease, install the front drive actuator and secure with the cap screws. GC063 4.
  • Page 102  NOTE: If gears are being replaced, use the existing shims.  NOTE: If the gear case housing is being replaced, proceed to the following Shimming Procedure/Shim Selection sub-section. Shimming Procedure/Shim Selection Shims 0402-405 0.051 CC875 0402-406 0.055 0402-407 0.059 0402-408 0.063 0402-409...
  • Page 103 GC059A GC072A 3. Install the bearing flange onto the gear case cover 6. Zero the dial indicator; then while holding the pinion making sure the alignment/locating pin engages the stationary, rock the ring gear assembly forward and locating hole in the cover; then make sure the bear- back and record the backlash.
  • Page 104 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 105 GC059B CC885 2. Using a propane torch, heat the area surrounding the  NOTE: The spider and ring gear assembly must be needle bearing to soften the Loctite. replaced as a complete unit. 3. Making sure the O-ring is properly positioned on the differential housing cover assembly, install the cover with existing cap screws (coated with green Loctite #609).
  • Page 106 CC888 CC891 2. Using a suitable driver, install the needle bearing into 5. Install the pinion housing. the gear case housing making sure the bearing is Removing/Installing Axle Seal seated.  NOTE: This procedure can be performed on a rear ...

  • Page 107: Drive Axles

    CC901 AG925 3. Install the front axles.  NOTE: Prior to installing the seal, apply High Perfor- mance #2 Molybdenum Disulphide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated. CAUTION Make sure the tool is free of nicks or sharp edges or the seal will be damaged.
  • Page 108 1. Using a clean towel, wipe away any oil or grease ! WARNING from the axle components. Make sure the ATV is solidly supported on the support 2. Inspect boots for any tears, cracks, or deterioration. stand to avoid injury. ...

  • Page 109: Rear Gear Case

    KC305 KC489 5. Install the wheel and tighten to 40 ft-lb (steel) or 80 AT THIS POINT  ft-lb (aluminum). For servicing the input shaft, pinion gear, needle bear- 6. Remove the ATV from the support stand and release ing, thrust button, and axle seal, see Front Differential in the brake lever lock.

  • Page 110: Hand Brake Lever/Master Cylinder Assembly

    5. Remove the hub assembly. Hand Brake Lever/Master 6. Remove the four cap screws securing the brake disc. Cylinder Assembly CLEANING AND INSPECTING 1. Clean all hub components. 2. Inspect all threads for stripping or damage.  NOTE: The master cylinder is a non-serviceable 3.

  • Page 111: Hydraulic Brake Caliper

    Hydraulic Brake Caliper do not allow brake fluid to contaminate them. ! 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 112 PR713A PR715 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury.
  • Page 113 PR719C PR238 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. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock”...

  • Page 114: Troubleshooting Drive System

    Troubleshooting Drive 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 1.

  • Page 115: Suspension

    Suspension Front A-Arms REMOVING The following suspension system components should be inspected periodically to ensure proper operation. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. A. Shock absorber rods not bent, pitted, or damaged. B.

  • Page 116: Rear A-Arms

    9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut. 11. Install the wheel and tighten to 40 ft-lb (steel) or 80 ft-lb (aluminum).

  • Page 117: Wheels And Tires

    ! WARNING 2. Inspect the A-arm for bends, cracks, and worn bush- Use only Arctic Cat approved tires when replacing tires. ings. Failure to do so could result in unstable ATV operation. 3. Inspect the frame mounts for signs of damage, wear, The ATV is equipped with low-pressure tubeless tires of or weldment damage.

  • Page 118: Troubleshooting

     NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally.  NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Steering/Frame/Controls - Measur- ing/Adjusting Toe-Out).
  • Page 119 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-382...

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