Arctic Cat 2015 XR Service Manual
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Arctic Cat 2015 XR Service Manual

Arctic Cat 2015 XR Service Manual

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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 Testing Oil Pump Pressure........116 General Specifications..........2 Liquid Cooling System ..........117 Torque Specifications............ 2 Troubleshooting ............119 Torque Conversions (ft-lb/N-m)........3 Electrical System ............120 Gasoline - Oil - Lubricant..........3 Battery...............120 Genuine Parts............... 4 Accessory Receptacle/Connector ......121 Preparation For Storage ..........

  • Page 4: General Information

    2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change Rack Mount Frame Gasoline (recommended) 87 Octane Regular Unleaded SUSPENSION COMPONENTS Engine Oil (recommended) Arctic Cat ACX All Weather A-Arm Frame (Synthetic) Knuckle Ball Joint Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid...

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

    Crank Balancer Shaft CAUTION Outer Magneto Cover Left-Side Cover Secondary Shaft Bearing Crankcase Half Do not use white gas. Only Arctic Cat approved gaso- Housing line additives should be used. * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609...

  • Page 6: Genuine Parts

    Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illus- The recommended oil to use is Arctic Cat ACX All trated Parts Manual for the correct part number, quantity, Weather synthetic which has been specifically formu- and description.

  • Page 7: Preparation After Storage

    7. Check the entire brake systems (fluid level, pads, will assure many miles and hours of trouble-free riding. etc.), all controls, headlights, taillight, brakelight, Arctic Cat recommends the following procedure to pre- and headlight aim; adjust or replace as necessary. pare the ATV.

  • Page 8: Periodic Maintenance

    This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV.  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.

  • Page 9: Valve/Tappet Clearance

    2. Replace any drain that is cracked or shows any signs of hardening or deterioration. CAUTION The drain to the right is the clean air section of the filter housing. Any leak of this drain will allow dirt into the engine intake causing severe engine damage.

  • Page 10: Spark Plug

    2. Using compressed air, blow any debris from around the spark plug. ! WARNING Always wear safety glasses when using compressed air. 3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole.

  • Page 11: Engine/Transmission Oil - Filter

    550/700 CF105A CF109M 2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen.  NOTE: If the screen or gasket is damaged in any way, it must be replaced. 3. Install the spark arrester assembly with gasket; then secure with the three cap screws.

  • Page 12: Liquid Cooling System

    If leakage or damage is case. detected, take the ATV to an authorized Arctic Cat ATV 11. Remove the oil level stick; the oil level must be dealer for service. Also, the coolant level should be within the operating range but not exceeding the checked periodically.

  • Page 13: Front Differential/Rear Drive Lubricant

    Front Differential/Rear Drive Lubricant CAUTION Inspect the oil for any signs of metal filings or water. If found, take the ATV to an authorized Arctic Cat ATV dealer for servicing. CAUTION 5. Pour recommended oil into each filler hole. Any lubricant used in place of the recommended gear lube could result in premature failure of the shock lim- iter.

  • Page 14: Nuts/Bolts/Cap Screws

    4. Install the left-side engine cover and seat making sure the seat locks securely in place. Nuts/Bolts/Cap Screws  NOTE: An E (Error) in the gear position icon indi- cates no signal or a poor ground wire connection in the circuit. Troubleshoot the harness connectors, Tighten all nuts, bolts, and cap screws.
  • Page 15 C. Remove the protective cap, install one end of a clear  NOTE: During the bleeding procedure, watch the hose onto the REAR bleeder screw, and direct the reservoir very closely to make sure there is always a other end into a container; then while holding slight sufficient amount of brake fluid.

  • Page 16: Burnishing Brake Pads

    4. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed. Checking/Replacing V-Belt REMOVING 1. Remove the right-side footrest and brake pedal (see Steering/Frame/Controls). PR237 C. Install the new brake pads. D. Secure the caliper to the knuckle and/or axle housing with new “patch-lock”...
  • Page 17 INSTALLING 1. Place the V-belt into position on the driven pulley and over the front shaft. CF364A GZ085  NOTE: The arrows on the V-belt should point in direction of engine rotation (forward). 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the front shaft.

  • Page 18: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing XR134A not broken, worn, or binding.

  • Page 19: Rear Body Panel/Rack

    Rear Body Panel/Rack REMOVING  NOTE: If the technician’s objective is to remove the rear rack, proceed to step 6. 1. Remove the seat; then remove the shift lever knob and side panels. 2. Remove the torx-head screws (three on each side) XR133A securing the rear body panel to the footwell.

  • Page 20: Lcd Gauge

    XR131A XR106 6. Remove the four lock nuts securing the rear body To install the gauge, connect the multi-pin connector and panel to the mounting tabs on the frame. Discard the press the gauge into the dash. lock nuts.  NOTE: Ensure the rubber mounting ring is oriented ! WARNING correctly on the tab and seats fully through the pod.
  • Page 21 4. Remove the four cap screws securing the handlebar caps to the steering post; then move the handlebar out of the way. Account for two handlebar caps. EPS007A 10. Remove four cap screws securing the EPS housing to the frame; then lift the assembly upward sufficiently to disengage the lower coupler and remove from the XR143 left side.
  • Page 22 3. Install the tie rods and secure with the slotted nuts. Tighten to 30 ft-lb; then install new cotter pins.  NOTE: If the slots do not align with the holes in the tie rod ends, tighten the nuts just enough to allow installation of the cotter pins.

  • Page 23: Handlebar Grip

    4. Connect the 2-pin and 8-pin connectors to the EPS assembly. 5. Install the steering post housing with plate to the frame and secure with two cap screws. Tighten to 20 ft-lb. 6. Install the handlebar and secure with the handlebar caps.

  • Page 24: Throttle Control

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

  • Page 25: Steering Knuckles

    ASSEMBLING AND INSTALLING Steering Knuckles 1. Install the bearing; then install the snap ring making sure it seats into the knuckle. REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 26: 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.

  • Page 27: Shift Lever

    AF786D AF789D 9. Measure the distance between the marks (at a height  NOTE: The distances from the inside rims to the parallel to the belly panel) at the front side; then frame tubes should be equal. If the measurements record the measurement.

  • Page 28: Front Bumper

    INSTALLING Muffler 1. Place the spring into position between the upper shift arm and shift lever; then making sure the O-rings are in place on the axle, secure the shift lever to the arm with the existing axle and nut. Tighten to 8 ft-lb. REMOVING 2.

  • Page 29: Seat

    2. Inspect the muffler internally by shaking the muffler 1. Disconnect the wiring harness connector (A), back and forth and listening for rattles or loose debris remove the headlight adjustment screw, and release inside the muffler. the clips; then remove the headlight assembly. ...
  • Page 30 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. 6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the verti- cal mark 5 cm (2 in.) below the horizontal mark on the aiming surface.

  • 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 appropriate components 3. Tire inflation pressure low 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 32: Engine/Transmission

    Arc- Description tic Cat ATV engine/transmission. Clutch Sleeve Hub Holder 0444-007  NOTE: Arctic Cat recommends the use of new gas- Connecting Rod Holder 0444-006 kets, O-rings, lock nuts, and seals and lubricating all Crankcase Separator/Crankshaft Remover...

  • Page 33: Specifications (500)

    Specifications (500) Specifications (550/700) VALVES AND GUIDES VALVES AND GUIDES Valve Face Diameter (max) (intake) 31.6 mm Valve Face Diameter (max) (intake) 35.0 mm (exhaust) 27.9 mm (exhaust) 30.5 mm Valve/Tappet Clearance (intake) 0.1016 mm (intake) 0.08-0.12 mm Valve/Tappet Clearance (cold engine) (cold engine) (max) (exhaust) 0.1524 mm...

  • Page 34: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Gasoline bad - contaminated 1. Drain gas - replace with clean gas 2. Valve clearance out of adjustment 2. Adjust clearance 3. Valve guides worn 3.
  • Page 35 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 36: Removing Engine/Transmission

    6. Remove the air inlet tube from air filter housing and throttle body. 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 ...
  • Page 37 550/700 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 38: Servicing Engine (500)

    NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components...
  • Page 39 NOTE: Care should be taken not to drop the C-ring down into the crankcase. 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.
  • Page 40 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 41: 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 con- Account for the gasket and two alignment pins. necting rod holder.
  • Page 42 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 43 2. Inspect the piston for seizure marks or scuffing. If piston is scored or galled, replace it with a new one. 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.
  • Page 44 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 45 Cleaning/Inspecting Cylinder Head 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect CAUTION the sealing surface for any indication of high spots. The cylinder head studs must be removed for this pro- A high spot can be noted by a bright metallic finish.
  • Page 46 NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not avail- able, use a lightweight petroleum-based oil. Thor- oughly clean cylinder after honing using soap and hot water.

  • Page 47: Installing Top-Side Components

    CF060A MD1344 2. If damaged, the camshaft must be replaced. 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; Installing Top-Side then remove the piston holder and seat the cylinder Components...

  • Page 48: Rocker Arms

    C. Cylinder Head/Camshaft 10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the D. Cylinder Head Cover/ piston is at top-dead-center. Rocker Arms 11. While holding the cam chain to the front, install the NOTE: Steps 1-4 in the preceding sub-section rear cam chain tensioner guide into the cylinder must precede this procedure.
  • Page 49 C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. CAUTION If any of the above factors are not as stated, go back to step 13 and carefully proceed.

  • Page 50: Left-Side Components

    FI612 MD1261 18. Rotate the crankshaft until the second cap screw 26. In a crisscross pattern starting from the center and securing the sprocket to the camshaft can be working outward, tighten the cap screws (from step installed; then install the cap screw (threads coated 25) to 8.5 ft-lb.

  • Page 51: Removing Left-Side Components

    Removing Left-Side Components A. Water Pump B. Speed Sensor C. Magneto Cover/ Stator Assembly 1. Remove the coolant hose connecting the water pump to the cylinder; then remove the water pump cover. FI544 4. Remove the water pump drive gear; then remove the speed sensor housing assembly.
  • Page 52 FI549 FI555 8. Using the Magneto Rotor Remover Set, break the G. Shift Shaft rotor/flywheel loose from the crankshaft; then remove the puller and crankshaft protector and H. Drive Gear remove the rotor/flywheel. NOTE: Steps 1-10 in the preceding sub-sections must precede this procedure.

  • Page 53: Servicing Left-Side Components

    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. FI564 FI572 REPLACING STARTER CLUTCH ASSEMBLY 1. Remove the cap screws securing the starter clutch assembly to the flywheel; then remove from the fly- wheel.
  • Page 54 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores. 3. Inspect the oil pressure relief valve for evidence of metal chips or contamination. Do not disassemble the valve. FI578 REPLACING STARTER GEAR BEARING 1.

  • Page 55: Installing Left-Side Components

    Installing Left-Side Components A. Starter Clutch/Gear B. Rotor/Flywheel 1. If removed, place the crankshaft bearing retainer into position. Apply red Loctite #271 to the three cap screws. Install and tighten the three cap screws securely. FI595A REPLACING MAGNETO COVER BEARINGS 1.
  • Page 56 FI559 FI596A 6. Install starter idler gears (1) and (2). 10. Install the water pump drive gear and secure with the nut. Tighten to 28 ft-lb. FI555A 7. Install the starter clutch gear onto the crankshaft; FI547 then install the rotor/flywheel key in the crankshaft. 11.

  • Page 57: Right-Side Components

    12. Install the water pump cover with a new O-ring and secure with the four cap screws. Tighten to 8 ft-lb. KC149A 2. Remove the cap screws securing the V-belt cover to the clutch cover; then slide the brake pedal outward FI538 and remove the V-belt cover.
  • Page 58 MD1035 MD1094 7. Remove the nut holding the driven pulley assembly; then remove the driven pulley assembly. MD1034 MD1068 8. Using an impact screwdriver, remove the three Phil- lips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5.
  • Page 59 MD1115 MD1016 13. Remove the cam chain. D. Centrifugal Clutch Assembly E. Oil Pump Drive Gear F. Oil Pump Driven Gear NOTE: Steps 1-10 in the preceding sub-section must precede this procedure. 11. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes.

  • Page 60: Servicing Right-Side Components

    19. Remove the four cap screws securing the oil strainer cap; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. MD1019 NOTE: Always use a new snap ring when install- ing the oil pump driven gear. MD1337 17.

  • Page 61: Installing Right-Side Components

    INSPECTING CENTRIFUGAL CLUTCH HOUSING 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. 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”...
  • Page 62 MD1208 MD1019 3. Place two alignment pins and the oil pump into posi- 5. Install the cam chain. tion on the crankcase and secure with the Phil- NOTE: Keep tension on the cam chain to avoid lips-head screws coated with red Loctite #271. Tighten to 8 ft-lb.
  • Page 63 8. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. MD1342 12. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loctite #271).

  • Page 64: Center Crankcase Components

    KC137 KC141 NOTE: The arrows on the V-belt should point in NOTE: At this point, the cap screw can be direction of engine rotation. removed from the driven pulley face. 15. Making sure the movable drive face rollers are in 17.

  • Page 65: Separating Crankcase Halves

    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. MD1313 Disassembling Crankcase Half NOTE: To aid in installing, it is recommended that the assemblies be kept together and in order. MD1006 NOTE: For steps 1-6, refer to illustration FI639A.
  • Page 66 FI659A FI646 FI661A FI653A 2. Remove the reverse idler assembly (B). Account for 4. Remove the gear shift shaft (F) noting the inner and and note the location of the inner bushing (1), idler outer washers. shaft (2), and outer washer (3). FI650A 5.

  • Page 67: Servicing Center Crankcase Components

    Checking Backlash 6. Remove the crank balancer driven gear (G) and account for a key; then remove the crankshaft bal- ancer shaft. NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1.
  • Page 68 NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be fol- lowed and the above “Tooth Contact/Shim Correc- tion” 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 69 CC289D H1-006 3. Acceptable gap range must be within specifications. 2. Acceptable width range must be within specifica- tions. Measuring Crankshaft (Runout) COUNTERSHAFT 1. Place the crankshaft on a set of V blocks. CAUTION 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- When disassembling the countershaft, care must be shaft.
  • Page 70 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 71 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 72: Assembling Crankcase Half

    FI662 MD1333 3. Apply a liberal amount of oil to the crankshaft bear- NOTE: The countershaft assembly is now ready ing. Using a propane torch, heat the bearing until the to be installed. oil begins to smoke; then slide the crankshaft assem- bly into place.
  • Page 73 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. FI658 6. Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end, install in the crankcase.

  • Page 74: Joining Crankcase Halves

    Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Loctite #5900 or suitable substitute sealant to the mating surfaces. Place the right-side half onto the left-side half.
  • Page 75 MD1008 CC871 4. From the left side, install the remaining crankcase 5. In a crisscross pattern, tighten the 8 mm cap screws until cap screws; then tighten only until snug. the halves are correctly joined; then tighten to 21 ft-lb. NOTE: Rotate the shafts back and forth to ensure NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the...

  • Page 76: Servicing Engine (550/700)

    Servicing Engine (550/700) Top-Side Components ..........74 Removing Top-Side Components ....... 74 Servicing Top-Side Components ........ 78 Installing Top-Side Components ......... 83 Left-Side Components ..........88 Removing Left-Side Components....... 88 Servicing Left-Side Components ........ 90 CC001D Installing Left-Side Components......... 92 ...
  • Page 77 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 78 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 79 CC024D CC032D 17. Using the Piston Pin Puller, remove the piston pin. Account for the opposite-side circlip. Remove the piston.  NOTE: It is advisable to remove the opposite-side circlip prior to using the puller. CC025D CC033D  NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Con- necting Rod Holder.

  • Page 80: Servicing Top-Side Components

    If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- Removing Valves nents be taken to a qualified machine shop for servicing.
  • Page 81 Installing Valves PISTON ASSEMBLY 1. Apply grease to the inside surface of the valve seals;  NOTE: Whenever a piston, rings, or pin are out of then place a lower spring seat and valve guide seal tolerance, they must be replaced. over each valve guide.
  • Page 82 CC280D CC127D 2. Measure the corresponding piston diameter at the Measuring Piston Pin (Outside recommended point above the piston skirt at a right Diameter) and Piston-Pin Bore angle to the piston-pin bore. Subtract this measure- ment from the measurement in step 1. The difference (clearance) must not exceed specifications.
  • Page 83 ATV-1024B CC128D CAUTION Measuring Cylinder Head Distortion Incorrect installation of the piston rings will result in 1. Remove any carbon buildup in the combustion engine damage. chamber. CYLINDER/CYLINDER HEAD 2. Lay a straightedge across the cylinder head; then ASSEMBLY using a feeler gauge, check the distortion factor between the head and the straightedge.
  • Page 84 CC129D CC390D Inspecting Cam Chain Guide 4. If any measurement exceeds the limit, replace the cylinder and piston. 1. Inspect cam chain guide for cuts, tears, breaks, or chips. Measuring Camshaft Runout 2. If the chain guide is damaged, it must be replaced. ...

  • Page 85: Installing Top-Side Components

    Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.  NOTE: If the journals are worn, replace the cam- shaft.
  • Page 86 CC023D CF057A 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover  NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 6. Place the chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 87 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 camshaft/sprocket assembly onto the cylinder ensuring the following. CD461  NOTE: At this point, oil the camshaft journals, cam lobes, and the three seating surfaces on the cylinder.
  • Page 88 CD464 CC012D 19. Rotate the crankshaft until the second cap screw 22. Install the cylinder head plug in the cylinder head securing the sprocket to the camshaft can be with the open end facing downward and toward the installed; then install the cap screw (threads coated inside.
  • Page 89 CD469 CC005D 25. Using a flat-blade screwdriver, rotate the adjuster 27. Apply a thin coat of Three Bond Sealant to the mat- screw inside the tensioner counterclockwise until all ing surfaces of the cylinder head and valve cover. tension is released; then install the cap screw into the end of the chain tensioner.

  • Page 90: Left-Side Components

    CC001D FI085A 33. If removed, install the spark plug. Tighten securely. 4. Remove the cap screws securing the speed sensor housing to the crankcase and remove the housing assembly; then remove the snap ring securing the speed sensor trigger to the shaft and remove the trig- Left-Side Components ger.
  • Page 91 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 92: Servicing Left-Side Components

    Servicing Left-Side Components INSPECTING STARTER CLUTCH/GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clock- wise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. CD952A If it moves or locks up both ways, the starter clutch must be replaced.
  • Page 93 FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install the 2. Thoroughly clean the gear hub; then apply a drop of new clutch and secure with the cap screws after green Loctite #620 to the bearing outer race and applying a drop of red Loctite #271 to the threads. press into the gear hub until even with the lower Tighten to 26 ft-lb using a crisscross pattern.

  • Page 94: Installing Left-Side Components

    FI590 CD950A 3. Install the new stator coil assembly and secure with three new “patch-lock” cap screws. Tighten to 15 ft-lb. 4. Place the stator wire harness hold-down into posi- tion; then install the crankshaft position sensor and secure with two cap screws. Tighten securely. 5.
  • Page 95 CD944 CD948A  NOTE: The sharp side of the snap ring should be facing outward.  NOTE: Once the gears are secured, remove the oil passage plug from the crankcase. 3. Install the two starter gear shafts; then install the two starter gears (with the beveled side of the intermedi- ate gear facing inward as noted in removing).
  • Page 96 PR434A PR431A 9. Install the magneto cover and secure with the cap  NOTE: Rotate the shift cam plate to ensure it ratch- screws. Tighten only until snug. ets with no binding. 10. Place the bushing into position on the crankshaft 7.

  • Page 97: Right-Side Components

    Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover D. Oil Pump 1. Remove the cap screws securing the CVT cover; then using a rubber mallet, gently tap on the cover CD069 tabs to loosen the cover. Account for two alignment 14.
  • Page 98 4. Remove the bolt (550) or nut (700) securing the fixed driven assembly; then remove the assembly. CD974A  NOTE: For steps 7-13, refer to illustration CC829B. H1-019  NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. PR388 5.
  • Page 99 CC596 CC606  NOTE: Account for and inspect the clutch housing seal. CD987 CF088A 9. Remove the two cap screws securing the gear posi- tion switch; then remove the switch. 10. Remove the nut (left-hand threads) securing the clutch shoe assembly (C). CD993 12.

  • Page 100: Servicing Right-Side Components

    13. Remove the snap ring securing the oil pump driven 2. Inspect the clutch shoes for wear or damage. If any gear (A); then remove the gear noting the direction shoe is worn to the bottom of the groove, replace the of the sides of the gear for installing purposes.

  • Page 101: Installing Right-Side Components

    DRIVEN PULLEY ASSEMBLY  NOTE: The driven pulley is a nonserviceable com- ponent. If the pulley faces, cam ramps, or sheave bushing are worn or loose, the pulley must be replaced as an assembly. Do not disassemble the driven pulley. Installing Right-Side Components CD988...
  • Page 102 CD985A PR399A CAUTION When installed correctly, the green alignment dot (or the word OUTSIDE) on the one-way clutch is visible. 9. Lightly grease the clutch housing seal; then insert the left fixed-drive spacer. CD984  NOTE: When installed correctly, the sides of the drive and driven gears will be flush with each other.
  • Page 103 H1-023 H1-020A 12. Place the driven pulley assembly into position and 16. Place the V-belt into position on the driven pulley secure with the bolt (550) or nut (700). Tighten to 80 and over the front shaft. ft-lb (550) or 162 ft-lb (700). GZ085 CF262 ...

  • Page 104: Center Crankcase Components

    18. With the vehicle in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush Disassembling Crankcase with the top of the driven pulley. Half 19. 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 105 CC668 CC675 3. Remove the shift shaft (H); then remove the two 7. Note the timing marks on the crank balancer assem- forks taking note of the direction of the tabs on the bly (B) gear and crankshaft (C) gear for assembling forks for assembling purposes.

  • Page 106: Servicing Center Crankcase Components

     NOTE: Thoroughly clean any sealant from the oil strainer cap. MT011A 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft. PR406 CAUTION Unless the secondary drive gear, bevel gear, or bear- ings require service, do not remove the secondary drive assembly from the case.
  • Page 107 Checking Backlash 1. If removed, install the secondary drive/bevel gear shaft into the crankcase; then tighten the nut to 59 ft-lb. 2. Install the secondary drive bearing support; then install the secondary driven output shaft into the crankcase. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear.
  • Page 108 Measuring Connecting Rod 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- (Small End Inside Diameter) shaft. 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer.
  • Page 109 COUNTERSHAFT GZ312 3. Remove the reverse driven gear dog. GZ281A 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.
  • Page 110 GZ319 GZ317A GZ318A GZ318 6. Remove the low driven gear. Account for a bearing, 2. Install the low driven gear locking washer; then bushing, and thrust washer. install the inner reverse driven gear washer. GZ316 GZ319B Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing;...

  • Page 111: Assembling Crankcase Half

    GZ286A GZ313A GZ287 GZ312 4. Install the outer reverse driven washer; then secure 6. From the opposite end of the countershaft, install the the reverse driven gear assembly with a snap ring. high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F).
  • Page 112 MT014 CD832B 2. Apply a liberal amount of engine oil to the crank-  NOTE: It will be necessary to rotate the crank bal- shaft bearing. Using a propane torch, heat the bear- ancer until the counterweight is facing away from the ing until the oil begins to smoke;...

  • Page 113: Joining Crankcase Halves

    CC674 CC668 7. Place a washer on the end of the gear shift shaft; then 10. Install the front and rear secondary driven shaft install the shaft assembly making sure the two holes assemblies into the left side of the crankcase making on the end of the shaft are positioned vertically.

  • Page 114: Installing Engine/Transmission

    6. From the left side, install the case half 6 mm cap 550/700 screws; then tighten only until snug.  NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 7. From the right side, install the 6 mm cap screws; then tighten only until snug.
  • Page 115 XR159A XR158A 7. Install the throttle body and secure with the clamp. 10. Place the air filter assembly into position and con- nect the crankcase breather securing it with the 8. Connect the coil connector (A) and O2 sensor con- clamp;...

  • Page 116: 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.

  • Page 117: Throttle Cable Free-Play

    INSTALLING 3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. 1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely. Engine RPM (Idle) 2. Install the air filter housing boot and secure with the two hose clamps.

  • Page 118: Testing Oil Pump Pressure

    5. Remove the master cylinder from the mounting  NOTE: Ensure the tab of the mounting bracket is in bracket; then remove the mounting bracket from the place on the gas tank. frame. 3. Secure the vent hose to the frame with cable ties (as noted during removing), then connect the gasline hose and fuel pump connector.

  • Page 119: Liquid Cooling System

    3. Start the engine and run at 3000 RPM. With the oil temperature at 60° C (140° F), the oil pressure gauge must read as specified. (8.5-10 psi) 0.6-0.7 kg/cm 550/700 1.2-1.5 kg/cm (17-21 psi)  NOTE: If the oil pressure is lower than specified, check for low oil level, or defective oil pump.

  • Page 120: Cooling Fan

    COOLING FAN Removing 1. Remove the radiator (see Radiator in this sub-sec- tion). 2. Remove the fan assembly from the radiator. Installing 1. Position the fan assembly on the radiator; then secure with existing hardware.  NOTE: The fan wiring must be in the upper-right XR151B position.

  • Page 121: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas 2. Air filter/housing contaminated 2. Clean or replace air filter/housing or replace Problem: Idling or low speed impaired Condition Remedy 1. Gas contaminated 1.

  • Page 122: Electrical System

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

  • Page 123: Accessory Receptacle/Connector

    Charging  NOTE: Arctic Cat recommends the use of the CTEK Brakelight Switch Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.

  • Page 124: Engine Coolant Temperature (Ect) Sensor

    ! WARNING Wear insulated gloves and safety glasses. Heated oil can cause severe burns. 3. On the ECT sensor when the temperature reaches 20° C (68° F), the meter should read approximately 2.45k ohms. 4. On the ECT sensor when the temperature reaches 50°...

  • Page 125: Power Distribution Module (Pdm)

     NOTE: Make sure the fuses are returned to their proper position according to amperage. Refer to the Power Distribution fuse block decal for fuse placement. Module (PDM) RELAYS The 4-pin relays are identical plug-in type. Relay func- The fuses are located in a power distribution module tion can be checked by switching relay positions.

  • Page 126: Efi Sensors/Components

    AR603D XR116A 2. The meter reading must be within specification. 2. On the sensor side of connector, connect the black (negative) test lead to one white wire pin; then con-  NOTE: If the meter does not read as specified, nect the red (positive) test lead to the other white wire pin.

  • Page 127: Speed Sensor

    6. Slowly move the ATV forward or backward; the meter must show 0 and 6-12 DC volts alternately. Speed Sensor  NOTE: If the sensor tests are within specifications, the LCD gauge must be replaced (see Steer- ing/Frame/Controls).  NOTE: Prior to testing the speed sensor, inspect the four-wire connector on the speed sensor for contami- To replace a speed sensor, use the following procedure.

  • Page 128: Electronic Power Steering (Eps)

    The electronic power steering (EPS) system is an elec- tro-mechanical device that utilizes 12 volt DC power to Electronic Power drive a motor linked to the steering shaft to assist the Steering (EPS) rider when rotating the handlebar. Rider steering inputs are detected by a torque-sensing transducer assembly within the EPS housing.

  • Page 129: Ignition Switch

    Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1321 Vehicle Speed Erratic Vehicle speed signal received by the Intermittent main harness, intermittent speed Correct EPS vehicle speed signal EPS changing at an unrealistic rate sensor, dirty speed senor or trigger wheel. condition* C1322 Engine RPM Lost Engine RPM signal received by the...

  • Page 130: Handlebar Control Switches

    1. Set the meter selector to the DC Voltage position.  NOTE: These tests should be made on the switch side of the connector. 2. Connect the red meter lead to either red wire; then connect the black meter lead to ground. RESISTANCE (HI Beam) 3.

  • Page 131: Drive Select Switch

     NOTE: If the meter shows more than 1 ohm of resis- tance, replace the switch. Front Differential Actuator System RESISTANCE (Reverse Override) The connector is the four-prong white one next to the steering post. To access the connector, the front rack and ...

  • Page 132: Starter Relay

    3. With the engine running at a constant 5000 RPM 2. Connect the red tester lead to the positive battery ter- (with the headlights on), the meter must show minal; then connect the black tester lead to the starter 14-15.5 DC volts. cable connection on the starter relay.

  • 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- 2.
  • Page 134 TESTING  NOTE: The fuel pump will cycle 5-10 seconds after the ignition key is turned on. ! WARNING 5. If the pump is producing fuel pressure that is out of Whenever any maintenance or inspection is made on specification, check all electrical connectors and ver- the fuel system during which there may be fuel leakage, ify the pump is getting proper voltage (battery volt- there should be no welding, smoking, open flames, etc.,...

  • Page 135: Regulator/Rectifier

     NOTE: If readings are erratic, clean the resistor  NOTE: If voltage rises above 15.5 DC volts, the reg- wiper and resistor with clean alcohol and retest. If ulator is faulty or a battery connection is loose or still not correct, replace the fuel level sensor. corroded.

  • Page 136: Ignition Timing

    1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the red/blue wire; then connect the black tester lead to the black wire. 3. With either brake applied, the meter must show bat- tery voltage.

  • Page 137: Throttle Position Sensor (Tps)

    2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. Throttle Position Sensor 3. Connect the red tester lead to the blue/brown wire (TPS) (B) and the black tester lead to the pink/black wire (A);...

  • Page 138: Gear Position Switch

    3. Using a multimeter, connect the black tester lead to the black socket (GND) on the analyzer and the red 550/700 tester lead to the white socket (VAR); then select the DC Voltage position. With the vehicle off, the gauge should read 0.66-0.70 (500) or 0.58-0.62 (550/700) and at Wide-Open Throttle it should read up to approxi- mately 3.88 (500) or 3.7 (550/700).

  • Page 139: Efi Diagnostic System

    WT541 3. Press the center button (SELECT) to enter diagnostic mode; cycle the display by pressing either the left or right button to step to the desired function.  NOTE: The gauge can be utilized dynamically (engine running/vehicle moving) statically (engine/vehicle stopped).
  • Page 140 Coolant (COOLANT)  NOTE: After engine has been running, IAT readings will be higher than outside air temperature due to engine and engine compartment heat as well as intake manifold heating. MAP (AIR PRESS) WT591 Display: Engine coolant temperature as measured by the ECT sensor.
  • Page 141 TPS (TPS) DTC: P0336, P0337, P0339 Usage: Verify engine speed signal from the following. 1. CKP (crankshaft position) sensor to ECM 2. ECM (CAN) signal to gauge (tachometer) 3. ECM (CAN) signal to EPS Speedometer (SPEED) WT539 Display: TPS position (0% closed, 95-100% WOT). DTC: P0121, P0122, P0123 Usage: Verify TPS signal and adjust throttle cable.
  • Page 142 Code Fault Description Possible Cause Fault Recovery Method C0063 Tilt Sensor Circuit High Sensor or interconnect harness shorted to battery power Correct condition* C0064 Tilt Sensor Circuit Low/SG/Open Sensor or interconnect harness open or shorted to chassis ground Correct condition* P0030 O2 Heater Intermittent/Open Heater or interconnect harness intermittent or open...
  • Page 143 Code Fault Description Possible Cause Fault Recovery Method P0630 VIN Not Programmed or Incompatible Verify the LCD gauge and ECM part numbers are correct for the vehi- Correct gauge and ECM cle model number and VIN VIN compatibility issue* P0642 Sensor Power Circuit Low One or more of the sensors defective or shorted to chassis ground Correct condition*...

  • Page 144: 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 145: 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. XR165A Reassembled Size New Housing Housing 3.

  • Page 146: Front Differential

    2. Remove the drain plug and drain the gear lubricant into a drain pan; then reinstall the plug and tighten to 45 in.-lb. XR164A 3. While holding the actuator firmly forward, tighten the front cap screw to hold the actuator in place; then install but do not tighten the two remaining cap ATV0082A screws.
  • Page 147 8. Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft; then using a rubber mallet, tap the end of the axle and free it from the knuckle assembly. XR170 14. Push the axle shaft firmly toward the differential to release the internal lock;...
  • Page 148 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 149 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 150 GC014 CD099A 3. Lubricate the input shaft with High-Performance #2 5. Place the pinion housing with new gasket onto the Molybdenum Disulphide Grease packing the boot differential housing; then secure with the existing ribs and splines; then assemble allowing excess cap screws.
  • Page 151 KX174 KX178 6. Place the differential with the open side down; then NOTE: If the cover is difficult to remove, pry on lift the housing off the spider assembly. Account for the cover in more than one recessed location. shim(s) and mark as right-side. 4.
  • Page 152 WC430 CC882 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing. CC883 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. CC878 3. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press.
  • Page 153 WC429 GC031A 2. Install the ring gear with shim in the gear case; then Shimming Procedure/Shim Selection while holding the pinion stationary, rock the ring gear forward and back to determine if any backlash exists. If no backlash exists, install a thicker shim Case-side Shims (Backlash) and recheck.
  • Page 154 GC033A GC039A 4. Install the existing shim or a 1.6 mm shim on the 6. Zero the dial indicator; then while holding the pinion cover side of the ring gear; then place the assembled stationary, rock the ring gear assembly forward and gear case cover onto the gear case and secure with back and record the backlash.
  • Page 155 2. Zero the dial indicator; then push the ring gear  NOTE: The spider and ring gear assembly must be toward the dial indicator and release. End-play replaced as a complete unit. should be 0.004-0.008 in. 3. Assemble the fork and sliding collar into the cover 3.
  • Page 156 6. Install the shift fork shaft w/spring into the housing making sure the shaft O-ring is positioned to the inside. CD110 Removing/Installing Axle Seal CC892  NOTE: This procedure can be performed on a rear 7. Install the shift fork assembly making sure the fork gear case.
  • Page 157 INSTALLING DIFFERENTIAL 1. Place the differential on the right side; then install into the frame with the shaft and flanges attached. Place the differential into position on the frame and install the cap screws (coated with blue Loctite #243) and lock nuts. Tighten to 38 ft-lb. XR152A 7.

  • Page 158: Drive Axles

     NOTE: Keeping the axle level will aid in removal. Drive Axles CAUTION Do not attempt to use a slide hammer or gear case/axle damage will occur. REMOVING REAR DRIVE AXLE 1. Secure the ATV on a support stand to elevate the wheels.
  • Page 159 CF636 ATV-1048 2. Place the white-striped end of the CV joint into a 3. Apply 80 grams (2/3 of contents) of grease from the vise. pack into the bearing housing.  NOTE: Steps 1-3 can be used to replace the out- board boot.

  • Page 160: Rear Gear Case

    6. Using an appropriate spanner wrench, tighten the hub nut (from step 3) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hex nut.  NOTE: If the cotter pin does not line up, always tighten to the next alignment.

  • Page 161: Hub

    2. Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge. Clearance should be 0.002-0.004 in. AF960A AT THIS POINT  For servicing the input shaft, pinion gear, needle bear- ing, ring gear, and axle seal, see Front Differential in GC058A this section.

  • Page 162: Hand Brake Lever/Master Cylinder Assembly

    XR012A XR012A 6. Using an appropriate hub retaining wrench, tighten  NOTE: Do not allow the brake calipers to hang from the hub nut (from step 4) to 200 ft-lb; then install and their cable/hose. spread a new cotter pin making sure each side of the pin is flush to the hex nut.
  • Page 163 2. Inspect the brake lever for elongation of the pivot hole. 3. Inspect the reservoir for cracks and leakage. 4. Inspect the banjo-fitting for cracks and deterioration and the condition of the fittings (threaded and com- pression). INSTALLING 1. Position the brake housing on the handlebar. Secure with clamp screws;...

  • Page 164: 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 PR237A 1. Secure the ATV on a support stand to elevate the wheel;...
  • Page 165 ASSEMBLING/INSTALLING 1. Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing, seals, and brake piston. CAUTION Make sure the seals are properly in place and did not twist or roll during installation.
  • Page 166 PR712 3. Apply high-temperature silicone grease (supplied PR238 with the O-ring kit) to the inside of the caliper holder bores and O-rings; then install the four O-rings into the caliper. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock”...

  • Page 167: 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 168: 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 169: 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. XR148A 7. Remove the cap screws securing the ball joints to the 2.
  • Page 170 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 with a cable tie and grommet. 1. Clean all A-arm components using a pressure 4. Secure the lower eyelet of the shock absorber to the washer.

  • Page 171: Rear A-Arms

    XR148A XR099 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten the wheel nuts in 20 ft-lb install the hub assembly onto the drive axle. increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminium wheel w/black nuts), or 80 ft-lb (aluminum wheel w/chrome nuts).
  • Page 172 XR096B XR096A 6. Remove the caliper (right side only). 10. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Discard the lock nuts.  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.

  • Page 173: Rear Sway Bar

    4. Apply grease on the drive axle splines; then install 9. Secure the shock absorber to the frame and A-arm the hub assembly onto the drive axle. with a cap screw and new lock nut. Tighten to 50 ft-lb. PR290 5.

  • Page 174: Wheels And Tires

    Adjust the air pressure as necessary to ! WARNING meet the recommended inflation pressure. Use only Arctic Cat approved tires when replacing tires. 2. Inspect the tires for damage, wear, or punctures. Failure to do so could result in unstable ATV operation.

  • Page 175: 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 176 NOTES...
  • Page 177 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-394...

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