Drive System/Brake System; Front Drive Actuator/Differential Lock - Arctic Cat 2015 XR Service Manual

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
M6 (Torx T-30 Recess) 8-9.5 ft-lb
M8 (Torx T-40 Recess) 25-31 ft-lb
M10 (Torx T-50 Recess) 37-45.5 ft-lb
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Description
Backlash Measuring Tool (24-Spline Axle)
Backlash Measuring Tool (27-Spline Axle)
CV Boot Clamp Tool
Hub Retaining Wrench
Internal Hex Socket
Pinion Gear/Shaft Removal Tool
Gear Case Seal Installer Tool
 NOTE: Special tools are available from the Arctic
Cat Service Department.
Front Drive
Actuator/Differential
Lock
 NOTE: The actuator is not a serviceable compo-
nent. If it is defective, it must be replaced.
 NOTE: The actuator will operate only when the igni-
tion switch is in the ON position.
The front drive actuator is located on the side of the front
drive input housing. With the engine stopped and the
ignition switch in the ON position, a momentary "whir-
ring" sound can be heard each time the drive select
switch is shifted or the differential lock is activated. If no
sound is heard, see Electrical System. If the actuator runs
constantly or makes squealing or grinding sounds, the
actuator must be replaced.
REMOVING
1. Disconnect the connector on the actuator harness.
2. Using a T-30 torx wrench, remove the mounting cap
screw from the driveshaft side of the actuator.
Reassembled
Housing 3. Remove the mounting cap screw from below the
6.5-9 ft-lb
21-25 ft-lb
31-38 ft-lb
p/n
0544-010
0544-011
0444-120
0444-270
0444-104
0444-127
4. Loosen but do not remove the mounting cap screw at
0444-224
INSTALLING
 NOTE: Make sure to properly align the differential
lock actuator lever with the hole in the differential
lock plunger.
1. Lubricate the O-rings on the actuator; then ensure
2. Align the actuator with the selector shaft and slide it
actuator on the suspension side.
the front of the actuator; then slide the actuator to the
rear enough to clear the slotted mounting tab and the
selector shaft.
that all mounting surfaces are clean and free of
debris.
forward onto the shaft taking care to engage the cap
screw in the slot of the front mounting tab.
XR165A
XR163A
XR164A
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