Arctic Cat 450 Service Manual
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Arctic Cat 450 Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2012
Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented
applications.
Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To
service models not included in this manual, please refer to the following publications:
•
2012 Y-12+ Service Manual
•
2012 T-14 Service Manual
•
2012 300 DVX/Utility Service Manual
•
2012 350 Service Manual
•
2012 425 Service Manual
•
2012 700 Diesel Service Manual
•
2012 450 XC Service Manual
•
2012 650 Service Manual
•
2012 550/700 Service Manual
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain
Manual
Table of Contents
August 2011

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  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information.
  • Page 2 Click on the blue text to go. Service M ervice rv c Manual M n a TABLE OF CONTENTS A A A A A A V V Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below.
  • Page 3 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-3 Torque Conversions (ft-lb/N-m) ....... 1-4 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........1-5 Genuine Parts ............1-5 Preparation For Storage.......... 1-6 Preparation After Storage........
  • Page 4 Gasoline (recommended) 87 Octane Regular Gasoline (recommended) 87 Octane Regular Unleaded Unleaded Engine Oil (recommended) Arctic Cat ACX All Weather Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) (Synthetic) Differential/Rear Drive Lubricant SAE Approved 80W-90 Front Differential/Rear Drive Lubricant...
  • Page 5 Frame Cam Chain Tensioner Guide Cylinder Shock Absorber (Lower) Lower A-Arm Stator Coil** Crankcase A-Arm Frame Starter Motor Crankcase Knuckle (450) A-Arm V-Belt Cover Crankcase Knuckle (1000) A-Arm Valve Adjuster Jam Nut Valve Adjuster Oil Fitting Engine Oil Pump** Crankcase...
  • Page 6 DRIVE TRAIN COMPONENTS (1000) Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m Engine Mount (Rear) Frame Front Differential Frame/Differential Bracket Rear Gear Case Frame ft-lb ft-lb ft-lb ft-lb Pinion Housing Differential Housing 35.4 69.4 103.4 Differential Housing Cover*** Differential Housing 36.7 70.7...
  • Page 7 CAUTION warm area. Do not use white gas. Only Arctic Cat approved gaso- line additives should be used. RECOMMENDED ENGINE/ TRANSMISSION OIL...
  • Page 8 Remove the air filter hous- exhaust system. ing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage 3. Check all control wires and cables for signs of Preserver, rapidly inject the preserver into the air wear or fraying.
  • Page 9 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Air Filter..............2-3 Valve/Tappet Clearance .......... 2-4 Testing Engine Compression ........2-5 Spark Plug(s) ............2-5 Muffler/Spark Arrester ..........2-6 Engine/Transmission Oil - Filter - Strainer ....2-6 Liquid Cooling System ..........
  • Page 10 * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. Manual...
  • Page 11 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 12 Feeler Gauge Procedure Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifica- tions, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within speci- fications. Tighten each jam nut securely after completing the adjustment.
  • Page 13 B. While holding the valve adjuster dial in place, use 5. While holding the throttle lever in the full-open posi- the valve adjuster handle and loosen the jam nut; tion, crank the engine over with the electric starter then rotate the tappet adjuster screw clockwise until the gauge shows a peak reading (five to 10 until friction is felt.
  • Page 14 ATV0052 CF104 When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn Engine/Transmission once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once the washer Oil - Filter - Strainer contacts the cylinder head.
  • Page 15 If leakage or damage is detected, take the 8. Start the engine (while the ATV is outside on level ATV to an authorized Arctic Cat ATV dealer for service. ground) and allow it to idle for a few minutes.
  • Page 16 3. On the 1000 models, move the panel rearward until free of the rack. On the 450 models, move the panel forward until free of the ATV.  NOTE: Steps 4-6 are for Mud Pro models; for other models, proceed to step 7.
  • Page 17 Front Differential/Rear Drive Lubricant  NOTE: On the 1000 models, the rear drive incorpo- rates a shock-limiting clutch pack in the gear case input assembly that is designed to cushion driveline shock. CAUTION Any lubricant used in place of the recommended gear 737-651B case lubricant could result in premature failure of the 4.
  • Page 18 2. Connect the new bulb assembly to the wiring harness connector; then insert into the headlight housing and rotate fully clockwise. To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing. ATV-0070C ...
  • Page 19  NOTE: An E (Error) in the gear position icon indi- cates no signal or a poor ground wire connection in Shift Lever the circuit. Troubleshoot the harness connectors, gear position switch connector, gear position switch, and LCD connector. CHECKING ADJUSTMENT Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at...
  • Page 20 C. Remove the protective cap, install one end of a clear hose onto one FRONT bleeder screw, and direct the other end into a container; then while holding slight pressure on the brake lever, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake lever.
  • Page 21 2. Measure the thickness of each brake pad. 5. Burnish the brake pads (see Burnishing Brake Pads in this section). 3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced. Burnishing Brake Pads Brake pads (both hydraulic and auxiliary) must be bur- nished to achieve full braking effectiveness.
  • Page 22 Secure the drive face with a washer and nut (coated with red Loctite #271). Tighten the nut to 147 ft-lb (450 models) or 165 ft-lb (1000 models). CAUTION Make sure the movable drive face plate is fully engaged onto the splines of the clutch shaft before tightening the nut or false torque readings may occur.
  • Page 23  NOTE: At this point, the push-bolt can be removed. 3. Rotate the V-belt and clutches until the V-belt is flush with the top of the driven clutch. 4. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws mak- ing sure the different-lengthed cap screws are in their proper location.
  • Page 24 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications (450)..........3-3 Specifications (1000)..........3-3 Troubleshooting ............3-4 Table of Contents (450) ........... 3-6 Table of Contents (1000) ........3-49 Manual Table of Contents...
  • Page 25 Magneto Rotor Remover Set 0444-254 from the frame. Oil Filter Wrench 0644-389  NOTE: Arctic Cat recommends the use of new gas- Piston Pin Puller 0644-328 Seal Protector Tool 0444-852 kets, lock nuts, and seals and lubricating all internal...
  • Page 26 Specifications (450) Specifications (1000) VALVES AND GUIDES VALVES AND GUIDES Valve Face Diameter (max) (intake) 35.0 mm Valve Face Diameter (max) (intake) 31.6 mm (exhaust) 30.5 mm (exhaust) 27.9 mm Valve/Tappet Clearance (cold engine) (intake) 0.08-0.12 mm Valve/Tappet Clearance (cold engine) (intake) 0.08-0.12 mm...
  • Page 27 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Repair - replace guides 3. Valve timing incorrect 3. Replace cam chain/sprocket and retime engine 4.
  • Page 28 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 29 2. Remove the left footwell, footrest, and footwell support assembly; then drain the coolant into a Table of Contents suitable container. (450) Removing Engine/ Transmission......3-6 Top-Side Components..........3-8 Removing Top-Side Components ......3-8 Servicing Top-Side Components......3-11 Installing Top-Side Components ......3-19 Left-Side Components ..........
  • Page 30 FI519A FI533A 8. Disconnect the crankcase breather hose from the 11. Remove the screws securing throttle arm cover to air filter housing and remove the air filter assem- the throttle body; then loosen the throttle cable bly. jam-nut and remove the throttle cable. 9.
  • Page 31 NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components...
  • Page 32 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 cylinder head.
  • Page 33 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 34 11. Remove the two nuts securing the right side of the NOTE: It is advisable to remove the opposite-side cylinder to the right-side crankcase half. circlip prior to using the puller. FI622A MD1219 12. Lift the cylinder off the crankcase taking care not NOTE: Support the connecting rod with rubber to allow the piston to drop against the crankcase.
  • Page 35 2. Place the cylinder head cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head cover in a figure eight motion. Inspect the sealing sur- face for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 36 1. Using a calipers, measure the width of the valve face. If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 37 ATV-1011A CC400D 4. Place a spring retainer over the valve springs; then 2. Remove each ring by working it toward the top of using the valve spring compressor, compress the the piston while rotating it out of the groove. valve springs and install the valve keepers. NOTE: When installing new rings, install as a complete set only.
  • Page 38 Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement does not meet specifications, the piston pin must be replaced. CC127D 2. Measure the corresponding piston diameter at a point 8 mm (0.3 in.) above the piston skirt at a right angle to the piston-pin bore.
  • Page 39 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 3. Maximum distortion must not exceed specifica- tions. MD1343A CAUTION Incorrect installation of the piston rings will result in engine damage.
  • Page 40 Inspecting Cam Chain Guide Measuring Camshaft Runout 1. Inspect cam chain guide for cuts, tears, breaks, or NOTE: If the camshaft is out of tolerance, it must chips. be replaced. 2. If the chain guide is damaged, it must be replaced. 1.
  • Page 41 CC005D CC287D 2. Place a strip of plasti-gauge in each of the cam- NOTE: If the journals are worn, replace the cam- shaft lands in the cylinder head. shaft; then measure the clearance again. If it is still 3. Place the valve cover on the cylinder head and out of tolerance, replace the cylinder head.
  • Page 42 CAUTION Installing Top-Side The cylinder should slide on easily. Do not force the cyl- Components inder or damage to the piston, rings, cylinder, or crank- shaft assembly may occur. A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and pis- ton pin bore with motor oil;...
  • Page 43 FI621 CD383 6. Place a new gasket into position on the cylinder. 12. With the alignment pin installed in the camshaft Place the alignment pins into position; then place and the cam lobes directed down (toward the pis- the head assembly into position on the cylinder ton), place the camshaft in position and verify that making sure the cam chain is routed through the the timing mark on the magneto is visible through...
  • Page 44 16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole. MD1359 14. Place the C-ring into position in its groove in the cylinder head. MD1363 CAUTION Care must be taken that the tab washer is installed cor- rectly to cover the alignment hole on the sprocket.
  • Page 45 19. Rotate the crankshaft until the first cap screw 27. Adjust valve/tappet clearance (see Section 2). (from step 17) securing the sprocket to the cam- 28. Place the two tappet covers with O-rings into posi- shaft can be addressed; then tighten to 11 ft-lb. tion;...
  • Page 46 4. Remove the water pump drive gear; then remove the speed sensor housing assembly. Account for two alignment pins, a gasket, and two seal wash- ers. FI538 2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins.
  • Page 47 8. Using the Magneto Rotor Remover Set, break the rotor/flywheel loose from the crankshaft; then remove the puller and crankshaft protector and remove the rotor/flywheel. FI559 12. Remove the shift detent cam arm and spring. FI550 9. Remove the flywheel key from the crankshaft; then remove the starter clutch gear.
  • Page 48 Servicing Left-Side Components INSPECTING STARTER CLUTCH/GEAR 1. Place the starter clutch gear onto the rotor/fly- wheel and attempt to rotate the starter clutch gear clockwise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should FI570 turn freely.
  • Page 49 REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft posi- tion sensor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor.
  • Page 50 FI593 MD1122 2. Install the starter motor and tighten the two cap screws securely. 3. Install the shift detent cam making sure the washer is installed. FI594 2. Clean the bearing bores in the housing and inspect closely for cracks or shiny areas indicating bearing movement.
  • Page 51 FI555A FI547 7. Install the starter clutch gear onto the crankshaft; 11. Install two alignment pins and a gasket on the then install the rotor/flywheel key in the crank- magneto cover; then install the water pump hous- shaft. ing assembly. Tighten the cap screws to 8 ft-lb. FI551A FI541A 8.
  • Page 52 13. Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely. Right-Side Components AT THIS POINT  To service center crankcase components only, proceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove KC142A and disassemble only those components which 3.
  • Page 53 MD1036 MD1068 5. Using a 6 mm cap screw threaded into the fixed 8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake driven face, spread the driven pulley by turning the plate. Remove the air intake plate. cap screw clockwise;...
  • Page 54 11. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes. FI630 14. Remove the oil pump drive gear cap screw. MD1286 12. Remove the left-hand threaded nut holding the centrifugal clutch assembly. CAUTION Care must be taken when removing the nut;...
  • Page 55 NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. MD1337 MD1020 AT THIS POINT  To service clutch components, see Servicing Right-Side Components sub-section.
  • Page 56 3. Check that the clutch shoe can only be rotated counterclockwise in respect to the clutch housing. If the clutch shoe locks up or turns in both direc- tions, the one-way clutch must be replaced. ATV1014 INSPECTING CENTRIFUGAL CLUTCH HOUSING 1.
  • Page 57 2. Place the strainer cap into position on the crank- case making sure the O-ring is properly installed and secure with the four cap screws; then tighten the oil drain plug to 16 ft-lb. MD1019 5. Install the cam chain. NOTE: Keep tension on the cam chain to avoid damaging the crankcase boss.
  • Page 58 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 Loc- tite #271).
  • Page 59 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 60 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 pur- poses. MD1313 Disassembling Crankcase Half NOTE: To aid in installing, it is recommended that the assemblies be kept together and in order.
  • Page 61 FI659A FI646 FI661A FI653A 2. Remove the reverse idler assembly (B). Account 4. Remove the gear shift shaft (F) noting the inner for and note the location of the inner bushing (1), and outer washers. idler shaft (2), and outer washer (3). FI650A 5.
  • Page 62 SECONDARY GEARS 6. Remove the crank balancer driven gear (G) and account for a key; then remove the crankshaft bal- ancer shaft. NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur.
  • Page 63 2. Clean the secondary driven bevel gear teeth of old If tooth contact pattern is comparable to an incorrect oil and grease residue. pattern, correct tooth contact according to the follow- ing chart. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear.
  • Page 64 Measuring Connecting Rod Measuring Crankshaft (Big End Side-to-Side) (Web-to-Web) 1. Push the lower end of the connecting rod to one 1. Using a calipers, measure the distance from the side of the crankshaft journal. outside edge of one web to the outside edge of the other web.
  • Page 65 4. Remove the splined washer; then remove the cir- clip securing the high-low sliding dog. Remove the sliding dog. FI664 2. Remove the splined washer; then remove the reverse driven gear along with the bearing and bushing. FI668 FI669 FI665 5.
  • Page 66 ASSEMBLING 1. With the high driven washer (1) on the counter- shaft, install the high driven gear bushing (3), bearings (2), and gear (4) on the countershaft; then install the washers (5) and secure with the snap-ring. FI667A FI671A FI666 4.
  • Page 67 FI663 MD1079 2. Install and tighten the output shaft flange nut to 59 ft-lb. Using a punch, peen the nut. FI662 NOTE: The countershaft assembly is now ready to be installed. MD1333 3. Apply a liberal amount of oil to the crankshaft bearing.
  • Page 68 MD1024 FI662 5. Install the key in the crank balancer shaft; then install the gear and aligning the timing marks, slide the gear into place. FI653 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.
  • Page 69 FI646 FI660A 10. Install the spacer (1), shaft (2), reverse idler gear, and washer (3). FI659A FI641A FI661A Joining Crankcase FI645 11. Install the secondary output driveshaft assembly Halves into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses;...
  • Page 70 FI639B CC871 5. In a crisscross pattern, tighten the 8 mm cap NOTE: Be sure to apply sealant to the inside screws until the halves are correctly joined; then radius of all cap screw locations and the entire tighten to 21 ft-lb. surface of the internal cap screw bosses.
  • Page 71 9. From the top side, install the ECT sensor connec- tor (C), fuel injector connector (D), MAP/IAT sen- sor connector (E), ISC connector (F), and the TPS connector (G). FI530B FI522A 10. Place the air filter assembly into position and con- nect the crankcase breather securing with the clamp;...
  • Page 72 3. Disconnect the IAT sensor connector; then loosen the clamp securing the inlet air boot to the throttle body Table of Contents (1000) and remove the air filter housing assembly. Removing Engine/ Transmission......3-49 Top-Side Components........... 3-53 Removing Top-Side Components ......3-53 Servicing Top-Side Components......
  • Page 73 GZ094A GZ107 8. Disconnect the stator coil connector and the crankshaft  NOTE: Using a suitable marker, mark the locations position sensor connector; then disconnect the gear posi- of any ties that are removed to relocate wiring out of tion switch connector from the gear position switch. the way.
  • Page 74 GZ103B GZ099A 10. Remove the E-clips securing the shift linkage to the 14. Remove the front and rear spark plug wires from the shift lever and shift shaft; then remove the shift link- spark plugs; then disconnect the primary wire con- age.
  • Page 75 GZ068 GZ028 17. Place a suitable drain pan under the radiator; then remove the radiator drain plug. Do not loosen the radiator cap at this time. GZ369A GZ086A 18. Remove the bleed screw from the water pump; then after coolant has drained, apply compressed air to the bleed opening to purge the remaining coolant from the system.
  • Page 76 Top-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- GZ104 assembly of components may be necessary.
  • Page 77  NOTE: Timing marks on the rotor/flywheel are stamped with an “F” (front cylinder) and “R” (rear cyl- inder) adjacent to the mark. GZ162 GZ063 GZ132A 4. Remove the cap screw on the end of the tensioner; then using a flat-blade screwdriver, turn the tensioner clockwise to remove the tension.
  • Page 78 GZ155 GZ136A 6. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft. GZ132B 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide.
  • Page 79 10. If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the second cylinder to top-dead-center of the compres- sion stroke; then repeat steps 2-9 on the other cylin- der head. AT THIS POINT ...
  • Page 80 Servicing Top-Side Components  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. GZ145 15.
  • Page 81 Removing Valves  NOTE: Index all valves, springs, and cotters to their original position when removing. When installing, all valve components should be installed in their original position. 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer.
  • Page 82 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 83  NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only. Cleaning/Inspecting Piston Rings 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45°...
  • Page 84 ATV-1070 GZ168 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. GZ169A 2. Install the second compression ring with the marking “E TOP” directed toward the top of the piston. ATV-1069 Measuring Piston Skirt/Cylinder Clearance...
  • Page 85 Cleaning/Inspecting Cylinder CAUTION 1. Wash the cylinder in parts-cleaning solvent. Incorrect installation of the piston rings will result in 2. Inspect the cylinder for pitting, scoring, scuffing, engine damage. warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Inspecting CYLINDER/CYLINDER HEAD Cylinder in this sub-section).
  • Page 86 CC127D CC283D 2. Wash the cylinder in parts-cleaning solvent. 2. Rotate the camshaft and note runout; maximum runout must not exceed specifications. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface Measuring Camshaft Lobe Height using a #320 grit ball hone.
  • Page 87 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely.  NOTE: Do not rotate the camshaft when measuring clearance.
  • Page 88 GZ159 GZ160A 3. Lubricate the inside wall of the cylinder; then using a 5. Install the coolant hose onto the crankcase union and ring compressor, compress the rings and slide the tighten the clamp. cylinder over the piston. Route the cam chain up C.
  • Page 89  NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. 13. With the cam lobes directed down (toward the pis- ton), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket.
  • Page 90 15. Place the tab-washer onto the sprocket making sure it 18. Rotate the crankshaft until the first cap screw (from covers the pin in the alignment hole. step 16) can be tightened; then tighten to 10 ft-lb. Bend the tab to secure the cap screw. AT THIS POINT ...
  • Page 91 GZ190B ATV-1027 21. Seat the cam sprocket onto the camshaft making sure CAUTION the alignment pin in the camshaft aligns with the Care must be taken that the tab-washer is installed cor- smallest hole in the sprocket; then place the cam- rectly to cover the alignment hole on the sprocket.
  • Page 92 CD465 CD468 25. Rotate the crankshaft until the first cap screw (from 28. Remove the cap screw from the end of the chain ten- step 23) can be addressed; then tighten to 10 ft-lb. sioner; then using a flat-blade screwdriver, rotate the Bend the tab to secure the cap screw.
  • Page 93 33. Lubricate the camshaft journals and lobes with engine oil; then place the valve cover into position. GZ201 GZ206  NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 34. Install the top side cap screws with rubber washers; then install the remaining cap screws.
  • Page 94 Left-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT  To service any one specific component, only limited dis- GZ224A assembly of components may be necessary.
  • Page 95 7. Remove the two cap screws securing the water pump to the crankcase; then remove the water pump. Account for an O-ring. GZ217 5. With the flywheel key removed, remove the starter ring-gear and spacer washer. GZ230A  NOTE: The water pump is a non-serviceable compo- nent and must be replaced as a complete assembly.
  • Page 96 GZ236A GZ235 10. Remove the cap screw securing the shift cam plate to 12. Remove the cap screws securing the oil filler cover the shift cam shaft and remove the shift cam plate; to the crankcase; then remove the cover. Account for then remove the shift shaft.
  • Page 97 3. Clean the countershaft and trigger splines throughly and install the inner snap ring onto the shaft; then apply green Loctite #620 to the trigger and counter- shaft splines and install the trigger. Secure with a flat washer and outer snap ring. GZ255 GZ253 GZ256...
  • Page 98 8. Install the shift shaft into the crankcase making sure the washers are properly located; then align the tim- ing reference marks and completely seat the shift shaft. GZ249 GZ258 GZ226 11. Place the key into the keyway in the crankshaft; then wipe all oil from the crankshaft surface and rotor/fly- wheel bore and install the rotor/flywheel onto the crankshaft aligning the keyway with the key.
  • Page 99 AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components GZ224A...
  • Page 100 CD966A GZ246B 3. Remove the V-belt. 4. Remove the nut securing the fixed driven assembly; then remove the assembly. GZ247A  NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 8. Remove the one-way clutch from the centrifugal PR388 clutch.
  • Page 101 INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the complete set.
  • Page 102 GZ241 GZ246B 2. Install the clutch cover alignment pins into the crank- 7. Making sure the alignment pins are correctly case, apply oil to the cover gasket, and install the installed, place a bead of silicone sealant on the mat- gasket onto the crankcase.
  • Page 103 GZ066 GZ075 9. Slide the fixed drive face onto the clutch shaft. CAUTION 10. Spread the faces of the driven pulley by threading in Make sure the splines extend beyond the drive face and a cap screw; then when the faces are separated, insert washer or a false torque reading and spline damage the belt and push down between the faces.
  • Page 104 Separating Crankcase Halves 1. Remove the oil strainer cap; then remove the oil strainer. GZ448A GZ445 GZ269A  NOTE: Do not disassemble these assemblies unless service is required. If disassembled, second- ary gear sets will have to be reset for backlash and gear contact (see Servicing Center Crankcase Com- ponents in this section).
  • Page 105 GZ272B GZ299A 3. Remove the snap ring securing the water pump idler shaft (C) in the crankcase; then remove the shaft and Disassembling Crankcase bearings. Half  NOTE: For steps 1-8, refer to illustration GZ474A. GZ463A 4. Remove the snap ring securing the oil pump driven gear (D) to the oil pump driveshaft;...
  • Page 106 8. Remove the reverse idler gear (I), shaft bushing, and two washers. DE677A GZ279  NOTE: Do not disassemble the countershaft assem- bly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. Servicing Center Crankcase Components GZ276  NOTE: Whenever a part is worn excessively, 6.
  • Page 107 MT011B MT008B 3. If installing the existing shaft, start with the shims  NOTE: Do not use a new lock nut at this time as this removed during disassembly or if installing a new procedure may have to be repeated. shaft, start with approximately 1.0 mm shims at point (D);...
  • Page 108  NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Shim Correction Under 0.127 mm (0.005 in.) Decrease Shim Thickness At 0.127-0.381 mm (0.005-0.015 in.) No Correction Required Over 0.381 mm (0.015 in.) Increase Shim Thickness 3.
  • Page 109 GZ357 GZ354A 3. Inspect the gerotor set for scoring, discoloration, or 6. Remove the oil seal from the oil pump cover. cracks; then using a feeler gauge, check the inner to outer rotor clearance. If measurements exceed speci- fications, the gerotor set must be replaced. GZ365 Assembling GZ355...
  • Page 110 CRANKSHAFT ASSEMBLY  NOTE: The crankshaft and connecting rod is a non-serviceable assembly. If any component is out of specification, the assembly must be replaced. Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore;...
  • Page 111 Measuring Crankshaft (Runout) COUNTERSHAFT 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- shaft. GZ281A CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, GZ489A gear) faces.
  • Page 112 GZ319 GZ312 3. Remove the reverse driven gear dog. GZ318A 6. Remove the low driven gear. Account for a bearing, GZ313A bushing, and thrust washer. 4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear. GZ316 Assembling GZ314...
  • Page 113 GZ318 GZ287 2. Install the low driven gear locking washer; then 4. Install the outer reverse driven washer; then secure install the inner reverse driven gear washer. the reverse driven gear assembly with a snap ring. GZ319B GZ288A GZ320B GZ314 3.
  • Page 114 GZ312 GZ347 6. From the opposite end of the countershaft, install the 3. Install the countershaft into the crankcase and secure high/low driven gear dog (A), thrust washer (B), with the snap ring (flat side away from the bearing). bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F).
  • Page 115  NOTE: It will be necessary to rotate the crankshaft back and forth to engage the teeth of the oil pump and countershaft gears. 6. Install the driveshaft; then with a flat washer on each end of the reverse idler assembly, install into the crankcase.
  • Page 116 AT THIS POINT  Proper transmission shifting should be verified by turn- ing the gear shift shaft to select High, Low, Neutral, and Reverse while rotating the input shaft and observing the countershaft rotation. AT THIS POINT  The right-side crankcase is now ready for installation to the left-side crankcase.
  • Page 117 Left-Side Components, and to Installing Top-Side Com- ponents. Installing Engine/Transmission  NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. GZ452A 1. Turn the front driveline to place the output drive yoke universal joint in the horizontal plane; then secure the driveshaft to the right and against the engine.
  • Page 118 GZ117A GZ064A 2. Install the engine/transmission into the frame from 8. Install the ignition coils and tighten the cap screws to the right side. 7 ft-lb; then connect the primary wires, grounds, and spark plug caps. 3. Rotate the driveshaft 90°; then lift the front of the engine sufficiently to engage the splined shaft into 9.
  • Page 119 GZ099A GZ090B 12. Connect the fuel injector, TPS connector (A), MAP sensor connector (B), and ISC valve connector (C). GZ372 11. Install the intake manifolds and tighten to 8 ft-lb; then install the throttle body and secure with the hose GZ094A clamps.
  • Page 120 16. Install the V-belt cooling duct and boots. Tighten securely. 17. Install the front body panel, footrests, foot wells, and front rack; then install the upper bumper sup- port-to-frame cap screws (see Section 8). 18. Connect the negative battery cable; then secure the battery with the tool tray and install the seat.
  • Page 121 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Electronic Fuel Injection .......... 4-2 Throttle Cable Free-Play ......... 4-4 Engine RPM (Idle)........... 4-5 Gas Tank ..............4-5 Oil Filter/Oil Pump ........... 4-5 Testing Oil Pump Pressure........4-5 Oil Cooler (1000) ............. 4-6 Liquid Cooling System ..........
  • Page 122 1. Turn the ignition switch to the OFF position; then remove the ignition switch key. ! WARNING  NOTE: Arctic Cat recommends the use of new gas- Do not turn the ignition switch to the ON position with kets, lock nuts, and seals and lubricating all internal the hoses removed.
  • Page 123 10. Remove the cap screws securing the intake pipe to the cylinder head and remove the throttle body assembly; then remove the intake pipe from the throttle body. Account for an O-ring. GZ091A 3. Loosen the clamp on the throttle body intake boot; then remove the air filter housing from the ATV.
  • Page 124 Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine is turned over or started. INSTALLING (450) 1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely.
  • Page 125 1. Connect the Tachometer to the engine or utilize the LCD (if equipped). 2. Connect the Oil Pressure Test Kit to the oil pressure test port (450 models) or the oil cooler to oil filter line (1000 models). FI092A 4. Remove the cap screws securing the gas tank to the frame.
  • Page 126 GZ118A 1000 Liquid Cooling System When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system to the bottom of the stand pipe in the radiator neck.
  • Page 127 THERMOSTAT Removing (450) 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. Removing (1000)  NOTE: The thermostat is located in a housing...
  • Page 128  NOTE: The fan wiring must be in the upper-right position. 2. Install the radiator. WATER PUMP (450) CC786A  NOTE: The water pump is a non-serviceable compo- Installing nent. It must be replaced as an assembly.
  • Page 129  NOTE: Always use a large container and have suffi- cient floor drying material available when draining the coolant in case of coolant spillage. 2. Remove the coolant hoses from the water pump; then remove two cap screws securing the water pump to the crankcase.
  • Page 130 3. Secure the water pump with the two cap screws and 3. Turn the ignition switch to the ON position. The fuel tighten securely; then connect the coolant hoses and pressure should build until the pump shuts off. Pres- secure with hose clamps. sure should read 3.0 kg-cm (43 psi).
  • Page 131 INSTALLING 1. Mark the new fuel pump with a reference mark in the same location as the removed pump; then place the new gasket on the pump. 2. Remove the material covering the fuel pump open- ing; then carefully guide the fuel pump into position taking care not to damage the float or float lever.
  • Page 132 Headlights ............. 5-14 Taillight - Brakelight ..........5-15 Ignition Timing ............5-15 Tilt Sensor ............. 5-15 Throttle Position Sensor (TPS) (450) ....5-16 Throttle Position Sensor (TPS) (1000 FIS).... 5-18 Throttle Position Sensor (TPS) (1000 TRV/1000 Cruiser/1000 Mud Pro) ... 5-20 Diagnostic Trouble Codes (DTC) (1000 FIS)..
  • Page 133 Maintenance Charging Electrical System  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two This section has been organized into sub-sections which weeks or as required by battery drain.

  • Page 134: Rpm Limiter

    Peak Voltage Reading Adapter must be used. If any other type of meter is used, readings may vary due to internal  NOTE: Arctic Cat recommends the use of the CTEK circuitry. When troubleshooting a specific component, Multi US 800 or the CTEK Multi US 3300 for battery always verify first that the fuse(s) are good, that the maintenance charging.
  • Page 135 VOLTAGE (Wiring Harness Side)  NOTE: The ignition switch must be in the ON position. 1. Set the meter selector to the DC Voltage position. VOLTAGE (Wiring Harness Connector) 2. Connect the red tester to the orange wire; then connect the black tester lead to the red/blue wire. 1.
  • Page 136 Engine Coolant Temperature (ECT) Sensor 1. Connect the meter leads (selector in OHMS posi- tion) to the sensor terminals. 2. Suspend the sensor and a thermometer in a con- tainer of cooking oil; then heat the oil.  NOTE: Neither the sensor nor the thermometer FI501A 3.
  • Page 137 RELAYS 450/450 TRV The 4-pin relays are identical plug-in type. Relay func- tion can be checked by switching relay positions. The relays are interchangeable.
  • Page 138 MANIFOLD ABSOLUTE PRESSURE/ SENSOR INLET AIR TEMPERATURE (MAP/IAT) To test the CKP sensor, see Stator Coil/Crankshaft Posi- SENSOR (450) tion (CKP) Sensor in this section. 1. Disconnect the MAP/IAT connector from the sen- MANIFOLD ABSOLUTE PRESSURE sor located on top of the throttle body.
  • Page 139  NOTE: If the meter does not read as specified, replace the sensor. Speed Sensor  NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for con- tamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position. CD071 2.
  • Page 140 Malfunction code P0635 will appear if one of the follow- 3. Disconnect 2-pin connector on the EPS assembly ing six conditions occur: and connect a volt meter set to DC voltage to the har- ness (black meter lead to BLK and red meter lead to 1.
  • Page 141 Ignition Switch The ignition switch harness connects to the switch with a four-pin connector. To access the connector, remove the ignition switch nut, remove the switch, and press the con- nector release tab. Pull the connector from the switch. CF274A 1.
  • Page 142  NOTE: If the meter shows more than 1 ohm of resis- 2. Connect the red tester lead to one red/yellow wire; then connect the black tester wire to the other red/yel- tance, replace the switch. low wire. The meter must show less than 1 ohm. RESISTANCE (LO Beam) 3.
  • Page 143 The meter must show 0 DC volts. 2. Test between the three yellow wires (450) or black wires (1000) for a total of three tests. 9. Connect the tester lead to the white/green wire in the supply harness.
  • Page 144 1. Set the meter selector to OHMS position. and a “click” should be heard from the relay. 2. Test between the three yellow wires (450) or gray  NOTE: If a “click” is heard and more than 1 volt is wires (1000) for a total of three tests.
  • Page 145 3. With the dimmer switch in the LO position, test The electronic control unit (ECU) is located beneath the the two outside connectors (LO beam). The meter seat near the battery (450) or under the fender near the must show battery voltage. taillight (1000).
  • Page 146  NOTE: If battery voltage is not shown in any test, inspect the LIGHTS fuse, battery, main wiring har- Tilt Sensor ness, connectors, or the left handlebar switch. Taillight - Brakelight ! WARNING Incorrect installation of the tilt sensor could cause sud- den loss of engine power which could result in loss of vehicle control resulting in injury or death.
  • Page 147 1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the rear frame. CD705A Throttle Position Sensor (TPS) (450) CD707 2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. INSPECTING 3.
  • Page 148 PR538A PR546A 8. Select the DC Voltage position on the meter and  NOTE: If the meter does not read as specified, turn the ignition switch to the ON position. The check for poor connections at the ECU or open/bro- meter should read approximately 4.5 DC volts ken wires in the wiring harness.
  • Page 149 Throttle Position Sensor (TPS) (1000 FIS) INSPECTING 1. Remove the left-side engine cover; then discon- nect the three-wire TPS connector plug. FI672 3. Using a multimeter, connect the black tester lead to the black socket (GND) on the analyzer and the red tester lead to the white socket (VAR);...
  • Page 150 5. Turn the ignition switch to the OFF position; then  NOTE: If the meter readings are as specified, check disconnect the battery (negative cable first). the main harness connector at the ECU main harness wiring. If the meter readings are not as specified, CAUTION replace the TPS and adjust to specifications (see INSTALLING/ADJUSTING in this sub-section).
  • Page 151 PR540A PR544 NOTE: Prior to testing the TPS, inspect the three-wire plug connector on the main harness and the three-pin plug on the TPS for contamina- tion, broken pins, and/or corrosion. 2. Make sure the ignition switch is in the OFF posi- tion;...
  • Page 152 REMOVING 1. Remove the left-side engine cover; then discon- nect the three-wire TPS connector plug. PR535A NOTE: If any meter reading is not as specified, replace adjust (see INSTALL- ING/ADJUSTING in this sub-section). PR544 2. Remove the screw securing the TPS to the throttle 6.
  • Page 153 3. Disconnect the diagnostic harness; then install the black rubber cap. 4. Install the seat making sure it locks securely in place. Diagnostic Trouble Codes (DTC) (450/1000 TRV/1000 Cruiser/1000 Mud Pro) ATV-112 If an EFI or related chassis component fails or an out-of-toler- 4.
  • Page 154 Input/ Gauge DTC Wrench Icon Status ECU PIN High/Low Variable Description Output Tilt Sensor Circuit High C0063 Tilt Sensor Circuit Low/SG/Open C0064 P0107 MAP Sensor Circuit Low/SG/Open P0108 MAP Sensor Circuit High/SP P0112 Intake Air Temp Sensor Circuit Low/SG P0113 Intake Air Temp Sensor Circuit High/Open Intake Air Temp Sensor Circuit Intermittent P0114...
  • Page 155 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. ECU defective 4. Replace ECU 5. Pick-up coil defective 5.
  • Page 156 Problem: Battery discharges too rapidly Condition Remedy 1. Charging system not charging 1. Check magneto - regulator/rectifier - circuit connections 2. Cell plates overcharged - damaged 2. Replace battery - correct charging system 3. Battery short-circuited 3. Replace battery 4. Electrolyte contaminated 4.
  • Page 157 SECTION 6 - DRIVE SYSTEM/ BRAKE SYSTEM TABLE OF CONTENTS Drive System/Brake System........6-2 Front Drive Actuator/Differential Lock...... 6-2 Front Differential ............6-3 Drive Axles ............6-16 Rear Gear Case ............ 6-19 Hub................ 6-22 Hand Brake Lever/Master Cylinder Assembly..6-23 Hydraulic Brake Caliper.........
  • Page 158 Drive System/Brake Front Drive System Actuator/Differential Lock  NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and  NOTE: The actuator is not a serviceable compo- are not designed to depict actual conditions. nent.
  • Page 159 AG928 AG926  NOTE: It is important to tighten this cap screw while INSTALLING the others are loose to ensure proper seating of the  NOTE: Make sure to properly align the differential actuator. lock actuator lever with the hole in the differential 5.
  • Page 160 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut and washer. AF896D 10. 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.
  • Page 161 AF897D PR725A 14. Remove the upper A-arm lock nuts and cap screws; 16. Remove the inner fender panels. then remove the A-arms. 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case; then remove the actuator.
  • Page 162 CD016 GC004A 20. Free the differential assembly from the frame mount- 2. Using a rubber mallet, remove the housing. Account ings; then shift the differential assembly forward for a gasket. Remove the fork, collar, and spring. enough to disengage the front driveshaft from the Note the location of all the components for assem- output yoke.
  • Page 163 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 164 GC014 CD099 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 gear case housing; then secure with the existing cap ribs and splines; then assemble allowing excess screws.
  • Page 165 GC003 KX177 3. Using a plastic mallet, tap lightly to remove the dif- ferential cover. Account for an O-ring. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly. Account for KX174 shim(s) and mark as right-side.
  • Page 166 Disassembling Pinion Gear  NOTE: Any service of the pinion gear or related bearings will require a new gear case/differential housing. The removal of the lock collar severely dam- ages the threads in the housing. 1. Using the 48 mm Internal Hex Socket, remove the lock collar securing the pinion gear assembly.
  • Page 167 CC884 CC891 3. Coat a new needle bearing and the bearing pocket of Shimming Procedure/Shim Selection a new gear case/differential housing with red Loctite #271; then using a suitable driver, install the bearing lightly seated against the bearing seats. Do not push Case-side Shims (Backlash) the bearing too far into the pocket.
  • Page 168 GC031A GC033A 2. Install the ring gear with shim in the gear case; then 4. Install the existing shim or a 0.063 in. 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 169 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.  NOTE: Once proper backlash and end play are established, the gear case can be assembled (see Assembling Differential Assembly in this sub-sec- tion).
  • Page 170 GC036B CF275A 5. Making sure the O-ring is properly positioned on the  NOTE: The spider and ring gear assembly must be differential housing cover assembly, install the cover replaced as a complete unit. with existing cap screws (coated with green Loctite #609).
  • Page 171  NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb. CF278 CAUTION Make sure the tool is free of nicks or sharp edges or CD103 damage to the seal may occur. 3. Repeat steps 1-2 for the opposite side. INSTALLING DIFFERENTIAL 1.
  • Page 172 AG925 AF896D 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this sec- tion). 6. Secure the upper A-arms with cap screws and lock nuts. Tighten to 50 ft-lb. AF895D 9. Install the brake calipers and secure with new “patch-lock”...
  • Page 173 2. Pump up the hand brake; then engage the brake lever lock. 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock. PR729B KX041 5. Remove the two brake calipers (right side only). ...
  • Page 174 Secure the knuckle to the A-arm with a cap screw and a new lock nut. Tighten to 35 ft-lb (450) or to 50 ft-lb (1000). 3. Place the hub into position on the axle followed by a hex nut.
  • Page 175 9. Check the front differential oil level and add oil as necessary. AT THIS POINT  For servicing the input shaft (450), pinion gear, needle bearing, ring gear, and axle seal, see Front Differential in this section. RING GEAR/THRUST BUTTON Removing 1.
  • Page 176 GZ176A GC058A 3. If clearance is as specified, remove the ring gear and thrust button; then place a drop of red Loctite #271 on the threads and tighten to 8 ft-lb (left-hand threads). 4. If clearance is not as specified, repeat steps 1 and 2 using thicker (clearance too great) or thinner (clear- ance too small) until correct specification is reached.
  • Page 177 GZ184A GZ184 2. Using a suitable seal driver, install a new oil seal into Cleaning and Inspecting the front of the input housing until the seal flush with the housing. 1. Wash all parts in parts-cleaning solvent and dry with compressed air.
  • Page 178 3. Remove the hex nut securing the hub. 4. Remove the brake caliper. GZ176 5. Using a new gasket, install the assembled rear drive input shaft/housing onto the rear drive gear case and secure with the three cap screws. Tighten to 23 ft-lb. PR243A 5.
  • Page 179 PR243A AF637D 6. Tighten the hex nut (from step 4) to 200 ft-lb; then 2. Place an absorbent towel around the connection to install and spread a new cotter pin making sure each absorb brake fluid. Remove the banjo-fitting from side of the pin is flush to the hex nut.
  • Page 180 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 181 PR235 PR238 5. Remove the caliper holder from the caliper and dis- CAUTION card the O-ring. Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV and do not reuse brake fluid.  NOTE: Whenever brake components are removed, disassembled, or repaired where brake fluid is exposed to air, drain all fluid and replace with new DOT 4 brake fluid from an unopened container.
  • Page 182 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 183 4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented.  NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock”...
  • Page 184 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 185 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-7 Troubleshooting ............7-8 Manual Table of Contents...
  • Page 186 Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. AF626D D.
  • Page 187 3. Remove the ATV from the support stand. 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 AF618D stand to avoid injury.
  • Page 188 AF616D AF610D 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.  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary.
  • Page 189 AF618D CD008 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten to 40 ft-lb (steel wheels) install the hub assembly onto the drive axle. or 80 ft-lb (aluminum wheels). 14. Remove the ATV from the support stand. Rear A-Arms REMOVING 1.
  • Page 190 2. Slide the knuckle onto the drive axle and into posi- tion on the A-arms; then secure the knuckle to the A-arms with cap screws and new lock nuts. Tighten to 35 ft-lb (450 models) or 50 ft-lb (1000 models). PR260 3. Tighten the hardware securing the A-arms to the 9.
  • Page 191  NOTE: Make sure each wheel is installed on its ! WARNING proper hub as noted in removing (the “rotation arrow” (if applicable) must indicate forward direction Do not mix tire tread patterns. Use the same pattern of rotation). type on front and rear. Failure to heed warning could cause poor handling qualities of the ATV and could cause excessive drive train damage not covered by war- ranty.
  • Page 192 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 193 SECTION 8 - STEERING/FRAME/CONTROLS TABLE OF CONTENTS Steering/Frame/Controls ..........2 LCD Gauge ..............2 Steering Post/Tie Rods ..........2 Handlebar Grip ............6 Throttle Control ............7 Steering Knuckles ............8 Measuring/Adjusting Toe-Out ........10 Shift Lever ..............11 Front Rack ..............11 Front Bumper Assembly ...........
  • Page 194 Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.
  • Page 195 4. Unlatch the storage compartment lid; then slide the storage compartment cover assembly forward and lift off. CD760 8. Using a suitable lift stand, raise the ATV enough to remove the front wheels. FI467A 5. Remove the storage compartment. CD685 ...
  • Page 196 EPS007A AL600D 12. Remove four cap screws securing the EPS housing to CLEANING AND INSPECTING the frame; then lift the assembly upward sufficiently to disengage the lower coupler and remove from the  NOTE: Whenever a part is worn excessively, left side.
  • Page 197 2. Place the upper steering post bearings into the hous- ings; then position on the steering post and secure the housings to the frame with two cap screws. Tighten to 20 ft-lb. FI464A CD760 3. Install the tie rods and secure with the slotted nuts. Tighten to 30 ft-lb;...
  • Page 198 INSTALLING (Electronic Power Steering Models) 1. Place the lower steering post into position; then secure the lower bearing flange to the frame with two cap screws. Tighten to 20 ft-lb. AF778D AL600D 2. Making sure the double spline is aligned to the slot in the lower coupler, install the EPS output shaft into the lower coupler;...
  • Page 199 2. Slide the grommet out of the lower half of the throt- tle control; then remove the cable from the actuator arm. KC310 AF676D 3. Remove the cap screw, lock washer, and washer securing the actuator arm to the throttle control lever. KC309A 2.
  • Page 200 7. Remove the two cap screws securing the ball joints in the knuckle. 8. Tap the ball joint end out of the knuckle; then remove the knuckle. 9. Remove the snap ring from the knuckle; then remove the bearing. AF679D 2.
  • Page 201 PR287A PR290A 2. Install the knuckle to the upper and lower ball joints 5. Install the hub assembly onto the splines of the shaft. and secure with the two cap screws. Tighten to 35 6. Secure the hub assembly with the nut. Tighten only ft-lb.
  • Page 202  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 203  NOTE: The front wheels do not have to be removed 2. Remove two cap screws, two self-tapping screws, and three nylon ties securing the left-side splash to adjust the tie rod. Also, care should be taken not to panel and remove the panel. disturb the handlebar position.
  • Page 204 CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Clean all bumper components with parts-cleaning solvent. 2. Inspect all welds for cracking or bending. INSTALLING 1. Place the front bumper assembly into position and install the through-bolt.
  • Page 205 5. Remove the cap screws and lock nuts securing the front rack to the frame; then remove the front rack. Account for the grommets and bushings. CD779 FI469A 6. Remove the side panels by pulling on them to release the tabs from the body; then remove the screws securing the rear of the front panel to the frame.
  • Page 206  NOTE: It may be necessary to rotate the body panel to the right to align the opening with the handlebar. CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary.
  • Page 207 FI467 CD691A 9. Install the steering post cover and secure with the 2. Remove the screws securing the foot pegs to the reinstallable rivets; then install and secure the radia- footrests; then remove the foot pegs and footwells. tor access panel. 3.
  • Page 208 Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muf- fler/exhaust pipe juncture. CD691A 3. Remove two machine screws securing the battery cover and remove the cover. CF138A 2. Slide the muffler rearward to clear the mounting lugs and remove the muffler.
  • Page 209 2. Place the rear rack in position with the bushings and secure with the cap screws and lock nuts. Tighten Taillight Assembly securely. 3. Install one shoulder screw and three plastic rivets (on each side) to secure the front of the rear body panel REMOVING to the footwells.
  • Page 210 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.

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