Arctic Cat 2016 Alterra 500 Service Manual
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Arctic Cat 2016 Alterra 500 Service Manual

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Summary of Contents for Arctic Cat 2016 Alterra 500

  • Page 1 SERVICE MANUAL www.arcticcat.com www.arcticcat.com...

  • Page 2: Table Of Contents

    2016 Alterra 500/550/700 Service Manual Table Of Contents General Information/Foreword ........2 Electrical System ............117 Specifications ............... 2 Battery...............117 Torque Specifications............ 2 Electronic Power Steering (EPS).......118 Torque Conversions (ft-lb/N-m)........4 Ignition Switch ............120 Gasoline - Oil - Lubricant..........4 Ignition Coil ...............121...

  • Page 3: General Information/Foreword

    2016 Tire Size Front - 25 x 8-12 Arctic Cat Alterra ATV models (see cover). The com- Rear - 25 x 10-12 plete manual is designed to aid service personnel in ser- Tire Inflation Pressure 0.35 kg/cm²...
  • Page 4 Torque ENGINE/TRANSMISSION Part Part Bolted To ft-lb N-m Torque Part Part Bolted To BRAKE COMPONENTS ft-lb N-m Brake Disc Clutch Shoe** (500) Crankshaft Brake Hose Frame Clutch Shoe** (550/700) Crankshaft Brake Hose Caliper/Cylinder Driven Pulley** (500) Driveshaft Master Cylinder Master Cylinder Clamp Driven Pulley** (550/700) Driveshaft Master Cylinder...

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

    69.4 103.4 36.7 70.7 104.7 CAUTION 38.1 72.1 106.1 39.4 73.4 107.4 Do not use white gas. Only Arctic Cat approved gaso- 40.8 74.8 108.8 line additives should be used. 42.2 76.2 110.2 RECOMMENDED ENGINE/ 43.5 77.5 111.5 TRANSMISSION OIL 10.9...

  • Page 6: Preparation For Storage

    1. Clean the ATV thoroughly. Arctic Cat recommends the following procedure to pre- pare the ATV for storage. An authorized Arctic Cat ATV 2. Clean the engine. Remove the cloth from the exhaust dealer should perform this service; however, the system.

  • Page 7: Periodic Maintenance/Tune-Up

    A. Throttle Lever Pivot B. Brake Lever Pivot C. Auxiliary Brake Pedal Pivot  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 8: Valve/Tappet Clearance

    ADJUSTING 3. Wipe any accumulation of oil or gas from the filter housing and drains.  NOTE: The seat, storage compartment cover assem- bly, compartment box, air filter/filter housing, and left-side/right-side splash panels must be removed for Valve/Tappet Clearance this procedure. A.

  • Page 9: Spark Plug

    5. While holding the throttle lever in the full-open posi- tion, crank the engine over with the electric starter until the gauge shows a peak reading (five to 10 compression strokes). COMPRESSION Model PSI Hot (WOT) PSI Cold (WOT) 95-115 120-140 80-120 125-145...

  • Page 10: Engine/Transmission Oil - Filter

    XR196 733-441A 4. Using the adjustable Oil Filter Wrench and a suitable wrench, remove the old oil filter. Account for and Engine/Transmission discard the O-ring. Oil - Filter  NOTE: Clean up any excess oil after removing the filter. OIL - FILTER 5.

  • Page 11: Front Differential/Rear Drive Lubricant

    12. Inspect the area around the drain plug and oil filter Inspect the oil for any signs of metal filings or water. If for leaks. found, take the ATV to an authorized Arctic Cat ATV dealer for servicing. 5. Pour recommended oil into each filler hole.

  • Page 12: Hydraulic Brake Systems

    ! WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop suddenly throwing the operator from the ATV. ADJUSTING SHIFT LEVER 1. Remove the seat and left side panel. 2.
  • Page 13 CHECKING/REPLACING PADS  NOTE: During the bleeding procedure, watch the sight glass very closely to make sure there is always a The clearance between the brake pads and brake discs is sufficient amount of brake fluid. If low, refill the res- adjusted automatically as the brake pads wear.

  • Page 14: Burnishing Brake Pads

    XR012A XR087A E. Install the wheel; then using a crisscross pattern, 2. Remove the cap screws securing the CVT cover; tighten the wheel nuts in 20 ft-lb increments to a final then using a rubber mallet, gently tap on the cover torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum tabs to loosen the cover.
  • Page 15 CD966A GZ085 4. Install the cap screw from the tool kit into the driven  NOTE: The arrows on the V-belt should point in pulley fixed face; then turn the cap screw clockwise direction of engine rotation (forward). to spread the pulley faces. Remove the V-belt. 2.

  • Page 16: Steering/Body/Controls

    Steering/Body/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 com- plete full-left and full-right turning capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.

  • Page 17: Rear Body Panel/Rack

    1. Remove the seat; then remove the shift lever knob and side panels. 2. Remove the torx-head screws (three on each side) securing the rear body panel to the footwell. XR133A CLEANING AND INSPECTING 1. Clean all components with warm soap and water. 2.

  • Page 18: Lcd Gauge

    CLEANING AND INSPECTING Steering Post/Tie Rods 1. Clean all body panel components with warm soap and water. 2. Inspect for cracks and loose rivets. REMOVING 3. Inspect for missing decals. 1. Remove the seat and side and side panels; then INSTALLING remove the center access cover.
  • Page 19  NOTE: For models not equipped with electronic power steering, proceed to step 13. 7. Remove the left front shock absorber; then remove the cap screws and nuts from the steering post to the EPS couplers. AF778D EPS005A 8. Pull upward on the steering post to disengage the upper coupler from the EPS assembly.
  • Page 20 7. Inspect the handlebar tube for cracks, wear, or unusual bends. 8. Inspect the handlebar grips for damage or wear. INSTALLING (Models Without Electronic Power Steering) 1. Place the steering post into position; then secure the lower bearing flange to the frame with two cap screws.

  • Page 21: Handlebar Grip

    AF778D XR123A 2. Grasp the end and remove the cap screw, plug, and end cap. INSPECTING 1. Inspect the grip for wear, cuts, or cracks. 2. Inspect the grip for deterioration. 3. If a grip is damaged, cut the grip lengthwise using a sharp knife or box cutter;...

  • Page 22: Steering Knuckles

    AF677D AF680D 4. Remove the actuator arm and account for a bushing. 3. Place the two halves of the throttle control onto the Note the position of the return spring for installing handlebar and secure with the two machine screws. purposes.
  • Page 23 3. Install the tie rod end and secure with the nut. Tighten to 30 ft-lb; then install a new cotter pin and spread the pin. XR166A CAUTION Use extreme care when removing the bearing. If the bearing is allowed to fall, it will be damaged and will XR148A 4.

  • Page 24: Measuring/Adjusting Toe-Out

     NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (with- out an operator but with Arctic Cat approved acces- sories). 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each side XR214A of the rear rack.

  • Page 25: Shift Lever

    XR213 733-559A Shift Lever REMOVING 1. Remove the seat, shift lever knob, and left side panel. 2. Remove the axle and nut securing the shift lever to the upper shift arm; then remove the shift lever. Account for a spring and two O-rings. INSTALLING AF778D 1.

  • Page 26: Belly Panel

    INSTALLING 1. With the bumper properly positioned, install the two bolts securing the lower bumper to the frame. Tighten to 35 ft-lb. 2. Install the two cap screws and nuts to secure the upper bumper to the mounting tabs; then tighten to 20 ft-lb.
  • Page 27  NOTE: The heat shield will be removed as an assembly with the right taillight. 2. Insert the taillight into position and secure with exist- ing screws. Tighten to 13 ft-lb; then connect the wir- ing harness. Checking/Adjusting Headlight Aim The headlights can be adjusted vertically and horizon- tally.

  • Page 28: Troubleshooting

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

  • Page 29: Engine/Transmission

    Arc- Valve Spring Tension @ 32.5 mm (outer) 17.23 kg (37.98 lb) tic Cat ATV engine/transmission. VALVES AND GUIDES (550/700)  NOTE: Arctic Cat recommends the use of new gaskets, Valve Face Diameter (max) (intake) 31.6 mm (exhaust) 27.9 mm...

  • Page 30: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start Condition Remedy 1. Battery discharged or defective 1. Test, charge, and/or replace battery 2. Carbon build-up in combustion chamber excessive 2. Run combustion chamber cleaner or clean combustion chamber 3.
  • Page 31 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 32: 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- ponents, Left-Side Components, or Right-Side Compo- XR137B nents, the engine/transmission does not have to be 7.
  • Page 33 550/700 XR156A XR151 12. Remove the clamp securing the throttle body to the 550/700 flange; then set the throttle body aside. 13. Disconnect the shift linkage from the shift lever. XR157 XR159A 14. Remove the snubber bracket from the left side of the engine.

  • Page 34: Servicing Engine (500)

     wise until it locks. NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. 1. Remove the cap screws securing the two tappet cov- ers.
  • Page 35 FI607A MD1131 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cyl- inder head. Account for an alignment pin.  NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase.
  • Page 36 FI616 CD211 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. FI617 FI623A AT THIS POINT  To service valves and cylinder head, see Servicing Top-Side Components sub-section. 10. Remove the cam chain guide. AT THIS POINT ...

  • Page 37: Servicing Top-Side Components

    FI622A MD1219 12. Lift the cylinder off the crankcase taking care not to  NOTE: Support the connecting rod with rubber allow the piston to drop against the crankcase. bands to avoid damaging the rod or install a connect- Account for the gasket and two alignment pins. ing rod holder.
  • Page 38 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. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 39 3. Inspect the perimeter of each piston for signs of “blowby” indicated by dark discoloration. “Blowby” is caused by worn piston rings, excessive carbon in ring grooves, or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove.
  • Page 40 Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration.
  • Page 41 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion.

  • Page 42: Installing Top-Side Components

    2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.  NOTE: If the journals are worn, replace the cam- shaft. Inspecting Camshaft Spring/Drive Pin 1. Inspect the spring and unloader pin for damage. CC390D 4.

  • Page 43: Rocker Arms

     NOTE: The two cylinder-to-crankcase nuts will be tightened in step 9. FI626  NOTE: The piston should be installed so the IN points towards the intake side. FI622A C. Cylinder Head/Camshaft 2. Place the two alignment pins into position. Place a new cylinder gasket into position;...
  • Page 44 MD1347 GZ190C 7. Install the four cylinder head cap screws with wash-  NOTE: When the camshaft assembly is seated, ers. Note that the two cap screws on the right side of make sure the alignment pin in the camshaft aligns the cylinder head nearest the cam sprocket are longer with the smallest hole in the sprocket.
  • Page 45 CAUTION Care must be taken that the tab washer is installed cor- rectly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. 17. Apply red Loctite #271 to the first cap screw secur- ing the sprocket and tab washer to the camshaft;...

  • Page 46: Left-Side Components

    FI608 FI602 23. Loosen the adjuster screw jam nuts; then loosen the 29. Install the spark plug and tighten securely; then adjuster screws on the rocker arms in the valve install the timing inspection plug. cover. 24. Apply a thin coat of Three Bond Sealant to the mat- Left-Side Components ing surface of the valve cover;...
  • Page 47 5. Remove the cap screws securing the magneto cover to the crankcase. Note the location of the two inter- nal cap screws and the two longer cap screws. FI539 FI596A 6. Remove the magneto cover and account for two alignment pins and the gasket. D.

  • Page 48: Servicing Left-Side Components

    FI551A FI560 10. Remove starter idler gears and their respective 13. Remove the snap ring securing the output drive gear shafts; then remove the starter motor. Account for an to the output shaft and remove the gear noting that O-ring on the starter drive housing. the hub flange is directed toward the crankcase.
  • Page 49 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 1. Support the starter clutch gear in a press making sure FI572 to support the hub around the entire circumference;...
  • Page 50 FI580 FI590 3. Install the new stator coil assembly and secure with INSPECTING STATOR/MAGNETO three cap screws. Tighten to 15 ft-lb. COVER ASSEMBLY 4. Place the stator wire harness hold-down into posi- 1. Inspect the stator for burned or discolored wiring, tion;...

  • Page 51: Installing Left-Side Components

    FI594 MD1086 2. Clean the bearing bores in the housing and inspect 4. Install the shift detent cam arm and spring. closely for cracks or shiny areas indicating bearing 5. Install the gear shift shaft assembly and washer mak- movement. Replace the housing if any of the above ing sure to align the alignment marks.

  • Page 52: Right-Side Components

    8. Install the rotor/flywheel and secure with the nut. Tighten to 107 ft-lb. C. Magneto Cover D. Water Pump  NOTE: Steps 1-8 in the preceding sub-section must precede this procedure. 9. Install two alignment pins and place the magneto cover gasket into position.

  • Page 53: Removing Right-Side Components

    4. Remove the movable drive face and spacer. Account for the movable drive face rollers and outer drive Removing Right-Side face cover. Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the pedal axle.
  • Page 54 MD1094 MD1115 7. Remove the nut holding the driven pulley assembly; D. Centrifugal Clutch Assembly then remove the driven pulley assembly. E. Oil Pump Drive Gear F. Oil Pump Driven Gear  NOTE: Steps 1-10 in the preceding sub-section must precede this procedure.
  • Page 55 MD1016 MD1019 13. Remove the cam chain.  NOTE: Always use a new snap ring when installing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. FI630 14. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT ...

  • Page 56: Servicing Right-Side Components

    2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Place the one-way clutch onto the clutch shoe assem- bly with the green dot or the word “OUTSIDE” directed away from the clutch shoe. MD1337 KC330 2.

  • Page 57: Installing Right-Side Components

    2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced.  NOTE: The oil pump is a non-serviceable compo- nent and must be replaced as a complete assembly. DRIVEN PULLEY ASSEMBLY ...
  • Page 58 MD1017 MD1115 10. Tighten the clutch cover cap screws to 8 ft-lb. MD1018 7. Install the clutch shoe assembly on the crankshaft; MD1117 then install the flange nut (left-hand thread) (coated 11. Install the air intake plate. Apply red Loctite #271 to with red Loctite #271).

  • Page 59: Center Crankcase Components

    KC134 KC138 13. Slide the fixed drive face assembly onto the front shaft. 14. 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 KC141 ...

  • Page 60: Separating Crankcase Halves

     NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes.
  • Page 61 FI659A FI653A 4. Remove the gear shift shaft (F) noting the inner and outer washers. FI661A 2. Remove the reverse idler assembly (B). Account for and note the location of the inner bushing (1), idler FI650A shaft (2), and outer washer (3). 5.

  • Page 62: Servicing Center Crankcase Components

    Correcting Backlash 7. Using Crankcase Separator/Crankshaft Remover with the appropriate crankshaft protector, remove the  NOTE: If backlash measurement is within the crankshaft. acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim.
  • Page 63 ATV-0105 CC290D 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal.
  • Page 64 H1-003A FI663 3. Zero the indicator and rotate the crankshaft slowly. CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications.  NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4.
  • Page 65 FI671 FI667 ASSEMBLING 4. Remove the splined washer; then remove the circlip securing the high-low sliding dog. Remove the slid- 1. With the high driven washer (1) on the countershaft, ing dog. install the high driven gear bushing (3), bearings (2), and gear (4) on the countershaft;...

  • Page 66: Assembling Crankcase Half

    3. Install the low driven bushing (10), bearing (9), and 5. Install the reverse dog on the shaft; then place the gear (11) on the countershaft; then install splined shift forks and shift shaft into position. washer (12). FI663 FI667A FI662 FI666 ...
  • Page 67 MD1024 MD1079 5. Install the key in the crank balancer shaft; then install 2. Install and tighten the output shaft flange nut to 59 the gear and aligning the timing marks, slide the gear ft-lb. Using a punch, peen the nut. into place.
  • Page 68 FI653 FI641A 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crank- case. FI645 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;...

  • Page 69: Joining Crankcase Halves

     NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws. FI661A Joining Crankcase Halves MD1008 4. From the left side, install the remaining crankcase cap screws; then tighten only until snug. 1.

  • Page 70: Servicing Engine (550/700)

    Servicing Engine (550/700) Top-Side Components............. 69 Removing Top-Side Components ........69 Servicing Top-Side Components........72 Installing Top-Side Components ........78 Left-Side Components............. 82 Removing Left-Side Components ........82 Servicing Left-Side Components ........84 Installing Left-Side Components........86 Right-Side Components ..........89 CC001D Removing Right-Side Components........
  • Page 71 CD211A CC013D 5. Loosen the cap screw on the end of the tensioner; 8. While holding the chain, slide the sprocket and cam- then remove the two cap screws securing the ten- shaft out of the cylinder head. sioner adjuster assembly and remove the assembly. ...
  • Page 72 AT THIS POINT  To service valves and cylinder head, see Servicing Top-Side Components sub-section. AT THIS POINT  To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC017D CC022D C. Cylinder D. Piston  NOTE: Steps 1-12 in the preceding sub-section must precede this procedure.

  • Page 73: Servicing Top-Side Components

    CC025D CC033D  NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Con- necting 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 74 If valves, valve guides, or valve seats require servicing or Water or parts-cleaning solvent must be used in con- replacement, Arctic Cat recommends that the compo- junction with the wet-or-dry sandpaper or damage to nents be taken to a qualified machine shop for servicing.
  • Page 75  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. ...
  • Page 76 2. Insert an inside dial indicator into the piston-pin 2. The ring with the orientation mark (MTOP or TOP) bore. The diameter must not exceed specifications. should be installed in the second (middle) groove Take two measurements to ensure accuracy. and the ring with the orientation mark (M or O) should be installed in the first (top) groove.
  • Page 77 3. Place the cylinder head on the Surface Plate covered 3. Place the cylinder on the surface plate covered with with #400 grit wet-or-dry sandpaper. Using light #400 grit wet-or-dry sandpaper. Using light pressure, pressure, move the cylinder head in a figure eight move the cylinder in a figure eight motion.
  • Page 78  NOTE: To produce the proper 60° cross-hatch pat- tern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air;...

  • Page 79: Installing Top-Side Components

    Installing Top-Side Components A. Piston B. Cylinder 1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston.  NOTE: The piston should be installed so the arrow points toward the exhaust. CC024D 4.
  • Page 80 CC020D CD461  NOTE: At this point, oil the camshaft journals, cam lobes, and the three seating surfaces on the cylinder. 14. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat”...
  • Page 81 16. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the cam- shaft/sprocket assembly onto the cylinder ensuring the following. CD464 19. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed;...
  • Page 82 CC012D CD469 22. Install the cylinder head plug in the cylinder head 25. Using a flat-blade screwdriver, rotate the adjuster with the open end facing downward and toward the screw inside the tensioner counterclockwise until all inside. tension is released; then install the cap screw into the end of the chain tensioner.

  • Page 83: Left-Side Components

    GZ194 CC001D 27. Apply a thin coat of Three Bond Sealant to the mat- 33. If removed, install the spark plug. Tighten securely. ing surfaces of the cylinder head and valve cover. 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.
  • Page 84 9. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter.  NOTE: The puller has left-hand threads. 10. Using Magneto Rotor Remover Set and the appropri- ate crankshaft protector, remove the rotor/flywheel assembly from the crankshaft.

  • Page 85: Servicing Left-Side Components

     NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. 14.
  • Page 86 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 1. Support the starter clutch gear in a press making sure FI572 to support the hub around the entire circumference;...

  • Page 87: Installing Left-Side Components

    FI580 FI595A INSPECTING STATOR COIL/MAGNETO COVER ASSEMBLY Installing Left-Side Components 1. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws.  NOTE: Plug the oil passage in the crankcase hous- 2.
  • Page 88 CD949 CD139  NOTE: The sharp side of the snap ring should be facing outward. 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing); then secure with the snap ring.
  • Page 89 PR433A CD954A CD934 CD927A 6. Install the shift cam stopper, spring, and two washers 8. Lubricate the magneto cover gasket with fresh (thick washer closest to the nut); then coat the engine oil; then place it into position on the two threads on the mounting stud with red Loctite #271 alignment pins.

  • Page 90: Right-Side Components

    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. AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary.
  • Page 91 CD966A CD973A 3. Remove the V-belt. CAUTION 4. Remove the bolt (550) or nut (700) securing the Care must be taken when removing the cover so the fixed driven assembly; then remove the assembly. cover gasket is not damaged.  NOTE: For steps 7-12, refer to illustration H1-029A.
  • Page 92 CC596 CC606 11. Using an impact wrench, remove the cap screws  NOTE: Account for and inspect the clutch housing securing the final drive carrier bearing housing (D); seal. then remove the housing and account for two align- ment pins. CF088A 8.

  • Page 93: Servicing Right-Side Components

    13. Using an impact driver, remove the three torx-head screws securing the oil pump; then remove the pump. CC446D DRIVE CLUTCH ASSEMBLY Disassembling and Inspecting CD988 1. Slide the sheave plate out of the movable drive sheave. Make note of each drive face plate damper Servicing Right-Side orientation before removing.
  • Page 94 ATV1152A CF381 3. Check the internal bushing of the movable drive DRIVEN PULLEY ASSEMBLY sheave and surface of the spacer. Replace as neces- Disassembling sary. Check the fixed drive sheave internal splines for excessive wear. Check for any broken cooling 1.
  • Page 95 WC418A WC383 4. Turn the wing nut counterclockwise to relax the 2. Inspect the cam shoes on the movable driven sheave spring. As the cam clears the key in the fixed driven for chipping, excessive scoring, or general condition. shaft, there will be a slight clockwise rotation of the cam.
  • Page 96 WC383A WC388 6. Inspect the spring for kinks by rolling on a flat sur- 3. Install the spring over the hub of the movable driven face. The spring should roll freely with no irregulari- sheave engaging the spring into the previously ties.

  • Page 97: Installing Right-Side Components

    WC414 WC412 6. Turn the wing nut clockwise to compress the spring being very careful that the cam correctly engages the fixed driven hub; then continue to tighten until the cam ramps are just above the cam shoes. WC419 9. Turn the wing nut counterclockwise slowly allowing the cam to contact the snap ring;...
  • Page 98 CD994 CD992 2. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the new “patch-lock” cap screws to 28 ft-lb. CD991 5. Grease the driven gear pin and insert the oil pump into the case. Tighten the oil pump screws to 8 ft-lb. Install the washer and pin;...
  • Page 99 6. Install the clutch shoe assembly and secure with the flange nut (threads coated with red Loctite #271). Tighten to 221 ft-lb. H1-023 11. Place the driven pulley assembly into position and secure with the bolt (550) or nut (700). Tighten to 80 ft-lb (550) or 162 ft-lb (700).

  • Page 100: Center Crankcase Components

    17. With the vehicle in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush with the top of the driven pulley. 18. Place the CVT cover gasket into position; then install the cover and secure with the cap screws. Tighten the cap screws to 45 in.-lb.
  • Page 101 DE677A A. Secondary Driven Shaft E. Driveshaft 5. Remove the countershaft assembly (D). Account for Assembly F. Reverse Idler Gear Assembly a washer on each end of the countershaft. B. Crank Balancer Assembly G. Gear Shift Shaft C. Crankshaft H. Shift Shaft with 2 Forks D.

  • Page 102: Servicing Center Crankcase Components

    CD826 PR406 8. Remove the crank balancer. CAUTION  NOTE: There is a flat spot on the crank balancer Unless the secondary drive gear, bevel gear, or bear- bearing flange to allow clearance past the crankshaft. ings require service, do not remove the secondary drive assembly from the case.
  • Page 103 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft. MT008B  NOTE: Do not use a new lock nut at this time as this procedure may have to be repeated. 5.

  • Page 104: Crankshaft Assembly

    MT005A CC290D 5. Acceptable backlash range is 0.127-0.381 mm 2. Maximum diameter must not exceed specifications. (0.005-0.015 in.). Measuring Connecting Rod Correcting Backlash (Small End Deflection)  NOTE: If backlash measurement is within the 1. Place the crankshaft on a set of V blocks and mount a acceptable range, no correction is necessary.
  • Page 105 CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction. In either case, complete disassembly and assembly will be required.
  • Page 106 GZ313A GZ318A 4. Remove the snap ring securing the reverse driven 6. Remove the low driven gear. Account for a bearing, gear and washer; then remove the washer and gear. bushing, and thrust washer. GZ314 GZ316 5. Remove the reverse driven washer; then remove the Assembling low driven gear locking washer.
  • Page 107 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ288A GZ319B GZ314 5. Install the reverse driven gear dog onto the counter- shaft and secure with a snap ring. GZ320B 3. Install the reverse driven bushing and bearing; then install the reverse driven gear.

  • Page 108: Assembling Crankcase Half

    GZ283B CC689 7. Install the two drive gear washers and the shift forks.  NOTE: If heating the bearing is not possible, the The countershaft is now ready for installation. crankshaft can be installed using a crankshaft install-  ing tool. NOTE: When installing the countershaft assembly, account for the washer on each end of the shaft.

  • Page 109: Joining Crankcase Halves

    CC675 CC669 6. Place a washer on each end of the countershaft 9. Install the reverse idler gear assembly noting the assembly; then install the assembly. positioning of the two washers, gear, bushing, and shaft. CC674 7. Place a washer on the end of the gear shift shaft; then CC668 install the shaft assembly making sure the two holes 10.

  • Page 110: Installing Engine/Transmission

    2. Lightly oil all bearings and grease all shafts in the 550/700 right-side crankcase. 3. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 4. From the right side, install the 8 mm cap screws; then tighten only until snug.
  • Page 111 XR160 XR158A 10. Place the air filter assembly into position and con- nect the crankcase breather securing it with the clamp; then connect the air inlet duct and secure with the hose clamps. 11. Install the spark plug cap. 12. Connect the air ducts to the CVT housing and tighten the clamps securely;...

  • Page 112: 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/transmission. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 113: Throttle Cable Free-Play

    INSTALLING Gas Tank 1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely. 2. Install the air filter housing boot and secure with the two hose clamps. ! WARNING 3. Connect the four electrical connectors to the throttle Whenever any maintenance or inspection is made on body components.

  • Page 114: Oil Pump

    4. Secure the gas tank mounting tab to the frame using the existing cap screws. Tighten to 8 ft-lb. 5. Install the battery tray and secure with the mounting clips and torx-head screw. Tighten the screw securely. 6. Install the battery and connect the battery cables (positive cable first);...

  • Page 115: Liquid Cooling System

     NOTE: If the oil pressure is lower than specified, While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after check for low oil level, or defective oil pump. the initial fill, shut the engine off, and then fill the cool- ...

  • Page 116: Troubleshooting

    THERMOSTAT Removing Removing 1. Remove the radiator cap; then remove the water pump drain and drain the coolant. 1. Drain approximately one quart of coolant from the cooling system. 2. Remove the two cap screws securing the thermostat housing to the cylinder head. Account for an O-ring and a thermostat.
  • Page 117 Problem: Starting impaired Condition Remedy 1. Battery discharged or defective 1. Test, charge, and/or replace battery 2. Gas contaminated 2. Drain gas tank and fill with clean gas 3. Air filter/housing contaminated 3. Clean or replace air filter/housing or replace Problem: Idling or low speed impaired Condition Remedy...

  • Page 118: Electrical System

    LED(s) are good, that the connections are clean and tight,  that the battery is fully charged, and that all appropriate NOTE: Arctic Cat recommends the use of the switches are activated. CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.

  • Page 119: Electronic Power Steering (Eps)

    EPS housing. These inputs are converted to  NOTE: Arctic Cat recommends the use of the electronic signals by the transducer and control circuitry CTEK Multi US 800 or the CTEK Multi US 3300 for to tell the motor which way to drive the steering shaft.
  • Page 120 Code Fault Description Fault Condition Possible Cause Fault Recovery Method C1301 Over Current EPS internal over-current condition Internal EPS Condition Correct EPS condition* has been detected C1302 Excessive Current Error EPS internal current measurement Internal EPS Condition Correct EPS condition* error has been detected C1303 Torque Sensor Range Fault EPS internal torque sensor range Internal EPS Condition...

  • Page 121: Ignition Switch

    TROUBLESHOOTING  NOTE: The EPS assembly is not serviceable and must not be disassembled or EPS warranty will be voided. 1. Check 30-amp EPS fuse and EPS relay (primary coil: 150 ohms ± 10%, secondary resistance <1 ohm with primary energized). 2.

  • Page 122: Ignition Coil

    Spark Plug Cap 4. The meter must show less than 1 ohm. 1. Connect the red tester lead to one end of the cap; 5. Turn the ignition switch to the LIGHTS position. then connect the black tester lead to the other end of 6.

  • Page 123: Switches

    1. Set the meter selector to the OHMS position. Switches 2. Connect the red tester lead to the yellow wire; then connect the black tester lead to the gray wire. 3. With the dimmer switch in the HI position, the meter must show less than 1 ohm.

  • Page 124: Fan Motor

    2. Connect the red tester lead to one blue wire; then connect the black tester wire to the black wire. The meter must show an open circuit. 3. Depress and hold the reverse override button. The meter must show less than 1 ohm. ...

  • Page 125: Front Differential Actuator System

    3. With the dimmer switch in the LO position, the ! WARNING meter must show battery voltage. Care should be taken to keep clear of the fan blades. 4. Move the red tester lead to the yellow/black wire.  NOTE: Fan motor resistance checks are not recom- With the dimmer switch in the HI position, the meter mended.

  • Page 126: Efi Sensors/Components

     NOTE: Battery voltage will be indicated from only one side of the fuse holder connector terminal; the EFI Sensors/Components other side will show no voltage.  NOTE: When testing the HI fuse holder, the head- FUEL INJECTOR light dimmer switch must be in the HI position; when testing the LIGHTS fuse holder, the headlight dim- mer switch can be in either position.

  • Page 127: Speed Sensor

    ENGINE COOLANT TEMPERATURE (ECT) SENSOR Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section). 1.
  • Page 128 Testing 5. Leave the black tester lead connected; then connect the red tester lead to the pink/white wire. ! WARNING 6. Slowly move the ATV forward or backward; the Whenever any maintenance or inspection is made on meter must alternate between 0 volts and battery the fuel system during which there may be fuel leakage, voltage.

  • Page 129: Tilt Sensor

    5. If the pump is producing fuel pressure that is out of 2. Remove the material covering the fuel pump open- specification, check all electrical connectors and ver- ing; then carefully guide the fuel pump into position ify the pump is getting proper voltage (battery volt- taking care not to damage the float or float lever.
  • Page 130 2. Turn the ignition switch to the ON position. The multimeter should read battery voltage. If battery voltage is not indicated, check the 30-amp main and 10-amp ignition fuses, wiring harness, or the ignition switch. 3. Remove the red tester lead and connect to the blue/brown wire (B).
  • Page 131  NOTE: If the vehicle is in warranty, removing or 1. With the key off, depress throttle lever to Wide Open Throttle (WOT). adjusting the TPS will void warranty. If the TPS is tested out of specification, the throttle body must be 2.

  • Page 132: Rpm Limiter

    RPM Limiter Component data can be retrieved using the CATT II. Utilize the Sensor Data screen. NOTE: The ATV is equipped with an ECM that cuts fuel spray and spark when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire. Incorrect Warranty Gear...

  • Page 133: Starter Motor

    INSTALLING Starter Motor 1. Apply a small amount of grease to the O-ring seal on the starter motor; then install the starter motor into the crankcase. Secure with two machine screws and wiring forms.  NOTE: The starter motor is a non-serviceable com- ponent.

  • Page 134: Electronic Control Module (Ecm)

    2. Depress and hold both left and right buttons together for approximately three seconds until “DIAGNOS- TIC” appears on the LCD. XR111 5. Depress the starter button and observe the multime- ter.  NOTE: If battery voltage is indicated, replace the WT541 3.
  • Page 135 Coolant (COOLANT) MAP (AIR PRESS) WT591 WT602 Display: Engine coolant temperature as measured by the Display: MAP in millibars and in./Hg. ECT sensor. DTC: P0107, P0108 DTC: P0116, P0117, P0118, P0119 Usage: Verify barometric pressure signal correct. Usage: Monitor coolant temperature to verify the follow- ing.
  • Page 136 Fuel Sensor (FUEL) 3. ECM (CAN) signal to EPS Speedometer (SPEED) WT545 Display: Fuel level signal from the fuel level sensor. WT543 DTC: C1400, C1401, C1402 Display: Vehicle speed signal. Usage: Check output of the fuel level sensor.* DTC: P0500 1.
  • Page 137 Code Fault Description Possible Cause Fault Recovery Method P0117 ECT Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition* P0118 ECT Sensor Circuit High/Open/SP Sensor or interconnect harness open or shorted to battery power Correct condition* P0119 ECT Sensor Circuit Intermittent Sensor or interconnect harness intermittent...
  • Page 138 Code Fault Description Possible Cause Fault Recovery Method P0615 Starter Relay Circuit Start switch/button, starter relay, gearswitch or interconnect Correct condition* harness erratic or intermittent P0616 Starter Relay Circuit Low Start switch/button, starter relay or interconnect harness Correct condition* intermittent or shorted to chassis ground P0617 Starter Relay Circuit High Start switch/button, starter relay or interconnect harness...

  • Page 139: 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 140: Drive System/Brake System

    Drive System/Brake System GENERAL INFORMATION The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values. Size New Housing Reassembled Housing XR165A M6 (Torx T-30 Recess) 8-9.5 ft-lb 6.5-9 ft-lb...

  • Page 141: Front Differential

    XR164A ATV0082A 3. While holding the actuator firmly forward, tighten 3. Remove the front wheels. the front cap screw to hold the actuator in place; then 4. Pump up the hand brake; then engage the brake lever install but do not tighten the two remaining cap lock.
  • Page 142 XR011C XR170 9. Pull the steering knuckle away from the axle. 14. Push the axle shaft firmly toward the differential to 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 differential/axle damage will occur.
  • Page 143 CD016 GC004A 18. Remove the four cap screws securing the output 2. Using a rubber mallet, remove the housing. Account flange; then shift the differential assembly forward for a gasket. Remove the fork, collar, and spring. enough to disengage the output flange assembly. Note the location of all the components for assem- bling purposes.
  • Page 144 CD107 KX219 5. Using a seal removal tool, remove the input shaft Assembling Input Shaft seal. Account for a spacer. 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.
  • Page 145 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. Slight pressure on the boot will be present during assembly. Secure with new clamps.  NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air;...
  • Page 146 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 147 3. Using a propane torch, heat the gear case housing to approximately 200° F; then install the pinion assem- bly. 4. Install the internal snap ring with the sharp side directed away from the bearing. CC879 4. Remove any reusable parts from the gear case hous- ing;...
  • Page 148 GC031A GC033A 2. Install the ring gear with shim in the gear case; then 4. Install the existing shim or a 1.6 mm shim on the while holding the pinion stationary, rock the ring cover side of the ring gear; then place the assembled gear forward and back to determine if any backlash gear case cover onto the gear case and secure with exists.
  • Page 149 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 (see Assembling Differential Assembly in this sub-section). Assembling Differential Assembly 1.
  • Page 150 CF266A CC892 7. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket. CF267A 4. Apply a liberal coat of grease to the O-ring; then install it on the assembled cover assembly making sure to seat the O-ring completely down around the CC893...
  • Page 151 Removing/Installing Axle Seal  NOTE: This procedure can be performed on a rear gear case. 1. Remove the seal using a seal removal tool. XR216 2. Align the four holes in the output flange and install the four cap screws (coated with blue Loctite #243). Tighten to 20 ft-lb.

  • Page 152: Drive Axles

    9. Secure the brake calipers to the knuckle with new “patch-lock” cap screws tightened to 20 ft-lb. XR099 5. Remove the two brake calipers (right side only).  NOTE: Do not allow the brake calipers to hang XR012A 10. Tighten the hub nut (from step 8) to 200 ft-lb. from their cable/hose.
  • Page 153 CLEANING AND INSPECTING  NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary. 1. Using a clean towel, wipe away any oil or grease from the axle components. CF638 3. To disengage the axle from the CV joint, sharply pull back on the axle;...

  • Page 154: Rear Gear Case

     NOTE: In the outboard boot, use the final 40 grams 8. Remove the ATV from the support stand and release the brake lever lock. (1/3 of contents) of grease from the pack in the bear- ing housing. INSTALLING FRONT DRIVE AXLE INSTALLING REAR DRIVE AXLE 1.

  • Page 155: Hub

    2. Remove both of the rear drive axles (see Drive Axles 1. Install the thrust button with shim into the gear case in this section). cover and tighten securely (left-hand threads). 3. Remove the four cap screws securing the output shaft to the rear gear case flange.
  • Page 156 XR099 PR290 3. Remove the nut securing the hub. 4. Secure the hub assembly with the hex nut. Tighten only until snug. 4. Remove the brake caliper. 5. Secure the brake caliper to the knuckle with two new “patch-lock” cap screws. Tighten to 20 ft-lb. XR012A ...

  • Page 157: Hand Brake Lever/Master Cylinder Assembly

    Hand Brake Lever/Master Cylinder Assembly  NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con- tainer.

  • Page 158: 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. REMOVING/DISASSEMBLING 1. Secure the ATV on a support stand to elevate the PR238 wheel;...
  • Page 159 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. 7.
  • Page 160  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” cap screws. Tighten to PR239C 20 ft-lb. 5.

  • Page 161: 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 162: Suspension

    CAUTION Suspension Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur. The following suspension system components should be 3. Remove the two cap screws and nut securing each inspected periodically to ensure proper operation. rear shock absorber to the frame and lower A-arm.

  • Page 163: Front A-Arms

    Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the cotter pin from the hub nut. Discard the XR148A cotter pin.
  • Page 164 XR155A XR154A 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount; then secure the hose to the A-arm 1. Clean all A-arm components using a pressure with a cable tie and grommet. washer. 4. Secure the lower eyelet of the shock absorber to the 2.

  • Page 165: Rear A-Arms

    8. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. Rear A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the wheels ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.
  • Page 166 XR097A XR104  CLEANING AND INSPECTING NOTE: Do not allow the brake caliper to hang from the cable/hose. 1. Clean all A-arm components using a pressure washer. 7. Remove the cap screws and lock nuts securing the shock absorber to the frame and lower A-arm; then 2.

  • Page 167: Rear Sway Bar

    Rear Sway Bar REMOVING 1. Remove and discard the cap screws and lock nuts securing the sway bar link to the lower A-arms on both sides. XR096B 7. Compress the hand brake lever and engage the brake lever lock; then tighten the hub nut (from step 5) to ft-lb.

  • Page 168: Wheels And Tires

    ! WARNING Install the wheel; then using a crisscross pattern, tighten the Use only Arctic Cat approved tires when replacing tires. wheel nuts in 20 ft-lb increments to a final torque of 40 Failure to do so could result in unstable ATV operation.

  • Page 169: 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 170 NOTES...
  • Page 171 ©2015 Arctic Cat Inc. Effective: September 2015 Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-682...

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