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: Table Of Contents
TABLE OF CONTENTS SHARE OUR PASSION. Click on blue text to go. Foreword General Information/Specifications Periodic Maintenance 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System 6. Drive System 400 TRV Suspension 550 FIS/TRV 650 FIS 8. Steering/Frame 700 FIS/TBX/TRV Thundercat Controls/Indicators 1000 TRV Cruiser...
Page 3 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-3 Torque Conversions (ft-lb/N-m) ....... 1-5 Tightening Torque (General Bolts) ......1-5 Break-In Procedure ..........1-5 Gasoline - Oil - Lubricant ........1-5 Genuine Parts ............1-6 Preparation For Storage..........
Page 4 2.1 L (2.25 U.S. qt) - Change Drive Belt Width (minimum) 28.5 mm (1.12 in.) Gasoline (recommended) 87 Octane Regular Unleaded Brake Fluid DOT 4 Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Taillight/Brakelight 12V/8W/27W Front Differential/Rear Drive SAE Approved 80W-90 Hypoid Headlight 12V/37W (2) Lubricant Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Page 5: Front Differential
ELECTRICAL COMPONENTS Output Flange Rear Flange Output Engine/Harness Ground Cap Crankcase Joint Screw Pinion Housing Differential Housing Coil (400 TRV/650)* Frame Differential Housing Cover*** Differential Housing Coil (EFI) Air Filter Housing Drive Bevel Gear Nut** Shaft STEERING COMPONENTS Driven Bevel Gear Nut**...
Page 6 Rear Gear Case V-Belt Cover Clutch Cover Input Flange Drive Pulley Nut** Clutch Shaft ENGINE/TRANSMISSION Movable Drive Face Nut** Clutch Shaft (400 TRV) Output Yoke Nut Driven Output Shaft Clutch Shoe** Crankshaft Secondary Shaft Bearing Crankcase Half Clutch Cover/Housing Assembly Crankcase Housing...
Page 7 (7 Marked Bolt) 24-48 in.-lb 6-8 ft-lb CAUTION 13-20 ft-lb Do not use white gas. Only Arctic Cat approved gaso- 29-43 ft-lb line additives should be used. Manual Section Back Next...
Page 8 Also, not recom- mended are racing, vegetable, non-detergent, and cas- tor-based oils. The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifi- ATV0049B cally formulated for use in this Arctic Cat engine.
Page 9 11. Check the spark plug(s). Clean or replace as nec- essary. Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free rid- ing. Arctic Cat recommends the following procedure to prepare the ATV. Manual Section...
Page 10 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 (Feeler Gauge Procedure) ........2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) (400/H1) ....2-5 Valve/Tappet Clearance (Valve Adjuster Procedure) (H2) ......2-6 Testing Engine Compression ........
Page 11 * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval and strainer inspection can be increased to every 1,000 miles or every year.
Page 12 Use the following procedure to remove the filter and which show common maintenance procedures for the inspect and/or clean it. Arctic Cat ATV. CLEANING AND INSPECTING NOTE: Arctic Cat recommends the use of new FILTER gaskets, lock nuts, and seals and lubricating all internal components...
Page 13 NOTE: Foam Air Filter Cleaner and Foam Air Fil- ter Oil are available from Arctic Cat. KX045A 2. Replace any drain that is cracked or shows any 6.
Page 14 CAUTION Valve/Tappet Clearance The feeler gauge must be positioned at the same angle (Valve Adjuster Procedure) as the valve and valve adjuster for an accurate mea- (400/H1) surement of clearance. Failure to measure the valve clearance accurately could cause valve component damage.
Page 15 NOTE: Rotating the valve adjuster dial counter- NOTE: At this point, the rocker arms and adjuster clockwise will open the valve/tappet clearance by screws must not have pressure on them. 0.05 mm (0.002 in.) per mark. NOTE: Use Valve Clearance Adjuster for this pro- 7.
Page 16 3. Remove the spark plug(s); then attach the high tension lead(s) to the plug(s) and ground the plug(s) on the cylinder head(s) well away from the spark plug hole(s). 4. Attach the Compression Tester Kit. NOTE: The engine should be warm (operating temperature) and the battery full charged for an accurate compression test.
Page 17 400/H1 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 18 7. Install the engine drain plug and tighten to 16 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil level stick/filler plug. CAUTION Any oil used in place of the recommended oil could cause serious engine damage.
Page 19 Front Differential/Rear Drive Lubricant NOTE: On the H2, the rear drive incorporates a shock-limiting clutch pack in the gear case input assembly that is designed to cushion driveline shock. CAUTION 737-651B Any lubricant used in place of the recommended gear 4.
Page 20 Headlights/Taillight- Brakelight HEADLIGHTS NOTE: The bulb portion of a headlight is fragile. HANDLE WITH CARE. When replacing a headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing.
Page 21 7. Adjust each headlight by turning the adjuster knob 2. With the ignition switch in the ON position, loosen clockwise to raise the beam or counterclockwise to jam nut (A) (left-hand threads); then loosen jam lower the beam. nut (C) and with the shift lever in the reverse posi- tion, adjust the coupler (B) until the transmission is in reverse and the (R) icon appears on the LCD.
Page 22 738-420A PR377C NOTE: During the bleeding procedure, watch the reservoir/sight glass very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the reservoir before the bleeding proce- dure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.
Page 23 PR377C PR376B NOTE: During the bleeding procedure, watch the NOTE: The brake pads should be replaced as a reservoir/sight glass very closely to make sure set. there is always a sufficient amount of brake fluid. If 4. To replace the brake pads, use the following proce- low, refill the reservoir before the bleeding proce- dure.
Page 24 3. Remove the nut securing the movable drive face; then remove the face. Account for the flat washer Burnishing Brake Pads and spacer. NOTE: Keep the drive face plate in contact with the drive face when removing or installing the Brake pads (both hydraulic and auxiliary) must be bur- drive face to prevent the rollers from falling out.
Page 25 GZ085 GZ485A NOTE: At this point, the push-bolt can be INSTALLING removed. 1. Place the V-belt into position on the driven pulley 3. Rotate the V-belt and clutches until the V-belt is and over the front shaft. flush with the top of the driven clutch. 4.
Page 26 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications (400)..........3-2 Specifications (H1) ..........3-3 Specifications (H2) ..........3-3 Troubleshooting ............3-4 400 Table of Contents ..........3-7 H1 Table of Contents..........3-48 H2 Table of Contents..........3-92 Manual Table of Contents...
Page 27 (max) 0.35 mm removed from the frame. (wobble method) Valve Guide Inside Diameter 5.000-5.012 mm NOTE: Arctic Cat recommends the use of new Valve Stem Outside Diameter (intake) 4.975-4.990 mm gaskets, lock nuts, and seals and lubricating all (exhaust) 4.955-4.970 mm...
Page 28 Specifications* Specifications* (H1) (H2) VALVES AND GUIDES VALVES AND GUIDES Valve Face Diameter (intake) 31.6 mm Valve Face Diameter (intake) 31.6 mm (exhaust) 27.9 mm (exhaust) 27.9 mm Valve/Tappet Clearance (cold engine) (intake) 0.1016 mm Valve/Tappet Clearance (cold engine) (intake) 0.1016 mm (exhaust) 0.1524 mm...
Page 29 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. Valves mistimed 3. Retime engine 4.
Page 30 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Main bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace crankshaft assembly 3. Connecting rod side clearance too large 3. Replace crankshaft assembly Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy...
Page 31 Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2. Valve springs weak 2. Replace springs 3. Valve timing incorrect 3. Re-time valve gear 4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder 5.
Page 32 2. Remove the heat shield; then remove the gas tank (see Section 4). Table of Contents 3. Remove the oil fittings from the engine and (400) account for two O-rings; then disconnect the oil temperature connector and cooling fan connector. Removing Engine/Transmission......
Page 33 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring. KC248 KC170 KC255 5. Remove the inlet air duct, air filter housing, and air silencer duct;...
Page 34 KC243 10. Lift the rear of the engine/transmission and swing NOTE: Arctic Cat recommends the use of new to the right; then tilt the assembly sufficiently to gaskets, lock nuts, and seals and lubricating all remove through the right-side frame opening.
Page 35 2. Remove the valve cover cap screws. Note the rub- ber washers on the four top-side cap screws; remove the valve cover. Note the orientation of the cylinder head plug and remove it. Note the loca- tion of the two alignment pins. MD1251 5.
Page 36 MD1131 CD211 7. Noting the timing marks for installing purposes, 10. Remove the cylinder head from the cylinder, drop the sprocket off the camshaft. While holding remove the gasket, and account for two alignment the cam chain, slide the sprocket and camshaft out pins.
Page 37 12. 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. MD1226A MD1219 13. 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 38 Removing Valves Servicing Top-Side NOTE: Keep all valves and valve components as Components a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation. NOTE: Whenever a part is worn excessively, 1.
Page 39 Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indi- cator. ATV1082A 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) ATV-1082...
Page 40 Servicing Valves/Valve Guides/Valve Seats 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 41 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 exceeds specifications, the piston pin must be replaced. CC400D 2. Remove each ring by working it toward the top of the piston while rotating it out of the groove.
Page 42 CC397D MD1343A 2. Measure the corresponding piston diameter at a CAUTION point 15 mm (0.6 in.) above the piston skirt at a Incorrect installation of the piston rings will result in right angle to the piston-pin bore. Subtract this engine damage. measurement from the measurement in step 1.
Page 43 CAUTION Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to the sealing surface may result. CC996 Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion CC997 chamber. Inspecting Cam Chain Guide 2.
Page 44 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 45 MD1261 CF061A 5. Match the width of the plasti-gauge with the chart NOTE: With the weight extended, the unloader found on the plasti-gauge packaging to determine pin should be flat-side out; with the weight camshaft to cylinder head and valve cover clear- retracted, the unloader pin should be round-side ance.
Page 46 NOTE: The two cylinder-to-crankcase nuts will be tightened in step 9. MD1213 2. Place the two alignment pins into position. Place a new cylinder gasket into position; then place a pis- ton holder (or suitable substitute) beneath the pis- MD1226A ton skirt and square the piston in respect to the C.
Page 47 MD1347 MD1192 9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to 28 ft-lb. Tighten the two lower cylinder head nuts (from step 8) to 20 ft-lb and the cylinder-to-crankcase nuts (from step 4) to 8 ft-lb. 10.
Page 48 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 correctly to cover the alignment hole on the sprocket.
Page 49 MD1137 MD1254 19. Rotate the crankshaft until the first cap screw 24. Install the cap screw and spring into the end of the (from step 17) securing the sprocket to the cam- cam chain tensioner. Tighten securely. shaft can be addressed; then tighten to 11 ft-lb. Bend the tab to secure the cap screw.
Page 50 29. Adjust valve/tappet clearance (see Section 2). 30. Place the two tappet covers with O-rings into posi- tion; then install and tighten the cap screws securely. MD1186 3. Using an appropriate side case puller and the 6 mm adapter, remove the left-side cover w/stator assembly.
Page 51 MD1194 MD1369 5. Install the crankshaft protector. MD1370 7. Remove the starter idler gear (No. 1) and starter MD1365 idler gear (No. 2). 6. Using Magneto Rotor Remover Set, break the rotor/flywheel assembly loose from the crankshaft. Remove the remover, the crankshaft protector, the rotor/flywheel, and the starter clutch gear.
Page 52 9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 11. Remove two starter motor cap screws. MD1122 2. Install the starter motor and tighten the two cap screws securely. 3. Install the shift detent cam making sure the washer KC217 is installed.
Page 53 Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the pivot shaft. Account for a flat washer. MD1305 7. Place the key into its notch; then slide the rotor/ flywheel (with the ring gear in place) over the crankshaft.
Page 54 MD1033 MD1118 4. Remove the movable drive face and spacer. 6. Remove the fixed drive face. Account for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assem- MD1035 bly; then remove the driven pulley assembly. MD1034 MD1068 8.
Page 55 12. Remove the gear position switch. Account for a spacer. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the posi- tions of the different-lengthed cap screws for KC326A 13. Remove the one-way clutch noting the direction of installing purposes.
Page 56 MD1016 MD1019 15. Remove the cam chain. NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 19. Remove oil pump driven gear. Account for the drive pin and thrust washer. MD1335 16. Remove the oil pump drive gear cap screw. MD1020 ...
Page 57 21. Remove the four cap screws securing the oil CAUTION strainer cap; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. Always replace clutch shoes as a complete set or severe imbalance could occur. ATV1014 INSPECTING CENTRIFUGAL CLUTCH HOUSING 1.
Page 58 KC331A MD1337 3. Check that the clutch shoe can only be rotated 2. Place the strainer cap into position on the crank- counterclockwise in respect to the clutch housing. case making sure the O-ring is properly installed If the clutch shoe locks up or turns either direction, and secure with the four cap screws;...
Page 59 MD1020 MD1018 7. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread) (coated with red Loctite #271). Tighten to 147 ft-lb. NOTE: The flat side of the flange nut should be directed towards the clutch shoe. CAUTION Care must be taken when installing the flange nut;...
Page 60 KC326B MD1342 13. Place the driven pulley assembly into position and B. Clutch Cover secure with the nut (threads coated with red Loc- C. Fixed Drive Face tite #271). Tighten to 147 ft-lb. D. Movable Drive Face NOTE: Steps 1-9 in the preceding sub-section must precede this procedure.
Page 61 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. 16. Making sure the movable drive face rollers are in 18.
Page 62 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 1. Remove the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the driven gear.
Page 63 MD1326 KC325 4. Remove the shift fork shaft and the outer shift 7. Remove the counterbalance gear. Account for the fork. key. 8. Remove the counterbalance shaft. MD1327 5. Remove snap ring and gear from the output side of the gear cluster. Remove the gear cluster and the MD1024 9.
Page 64 10. Remove the secondary drive gear/secondary NOTE: Continue to remove, measure, and install driven gear retaining nut. From inside the crank- until backlash measurement is within tolerance. case using a rubber mallet, drive out the output Note the following chart. shaft assembly.
Page 65 ATV-0104 CC290D 2. Maximum diameter must not exceed specifica- Correcting Tooth Contact tions. Measuring Connecting Rod NOTE: If tooth contact pattern is comparable to (Small End Deflection) the correct pattern illustration, no correction is necessary. 1. Place the crankshaft on a set of V-blocks and If tooth contact pattern is comparable to an incorrect mount a dial indicator and base on the surface pattern, correct tooth contact according to the follow-...
Page 66 Disassembling 1. Remove the reverse driven gear dog; then remove the circlip securing the reverse driven gear. 2. Remove the reverse driven gear and account for the washer, bushing, and bearing. 3. Remove the low driven gear washer; then remove the low driven gear.
Page 67 NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installer. 4. Rotate the crankshaft so the counterweight is toward the rear of the engine. Install the counter- balance shaft. MD1199 MD1024 5. Keeping the counterbalance gear timing mark aligned with the one on the crankshaft gear, install the key and the counterbalance gear.
Page 68 MD1032 MD1357 11. Install the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the driven gear. NOTE: Align the bearing alignment pin on the secondary output shaft. Joining Crankcase Halves MD1198 1.
Page 69 Installing Engine/Transmission 1. From the right side, place the engine/transmission into the frame tilting the top-side forward to clear the frame member. MD1008 4. From the left side, install the remaining crankcase cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws.
Page 70 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal. Tighten the cap screws evenly to 20 ft-lb and install the muffler retainer springs. KC235 KC237 KC236 5.
Page 71 KC245A KC248 8. Install the air filter housing onto the frame; then 10. Connect the oil temperature connector and cooling connect the inlet air duct, air silencer duct, and fan connector; then using new O-rings, install the intake housing to carburetor boot and tighten all oil fittings onto the crankcase and secure with the hose clamps securely.
Page 72 11. If the brake pedal was removed during disassem- bling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. Tighten to 25 ft-lb. KC149A 12. Install the heat shield; then install the gas tank (see Section 4).
Page 73 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery and Table of Contents the battery vent hose; then remove the battery. (H1) CAUTION Battery acid is harmful if it contacts eyes, skin, or Removing Engine/Transmission......
Page 74 8. Remove the vacuum hose and the fuel-pump- to-carburetor hose (650) or gasline hose connector from the fuel rail (EFI). CD787 CD766A CD786 11. Remove the clamp securing the cooling duct boot to the V-belt housing; then remove the cooling duct boot from the V-belt housing outlet.
Page 75 13. Secure the carburetor/throttle body assembly up and away from the engine. 14. Remove the E-clip securing the shift rod to the engine shift arm; then allow the shift rod to swing forward and hang straight down from the shift lever.
Page 76 CD797A KC201A 22. Disconnect the temperature sensor lead from the 25. Remove the engine mounting through-bolts. wiring harness. Account for all mounting hardware. CD788 CD809 26. Raise the rear of the engine enough to allow the 23. Remove the spark plug wire from the spark plug; rear output flange to clear the output flange joint.
Page 77 CD812A CD773 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 CD813 To service any one specific component, only limited 28.
Page 78 CC001D CD211A 3. Loosen the cap screw on the end of the tensioner; NOTE: Keep the mounting hardware with the cov- then remove the two cap screws securing the ten- ers for assembly purposes or thread them back sioner adjuster assembly and remove the assembly. into the head to keep them separated.
Page 79 CC013D CC017D 6. While holding the chain, slide the sprocket and camshaft out of the cylinder head. CC018D CC014D 7. Remove the cap screw securing the chain ten- sioner (account for a washer); then remove the ten- sioner. CC016D 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins;...
Page 80  AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC025D CC022D C. Cylinder D. Piston NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. 10. Loosen the clamp securing the coolant hose to the union;...
Page 81 NOTE: Whenever a valve is out of tolerance, it must be replaced. Cleaning/Inspecting Valve Cover NOTE: If the valve cover cannot be trued, the cyl- inder head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. 2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper.
Page 82 2. Acceptable diameter range (intake valve) must be within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. CC132D 2. Remove the valve seal and the lower remaining spring seat.
Page 83 3. If a valve guide is out of tolerance, it must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing. CAUTION ATV-1011A If valves are discolored or pitted or if the seating sur- 4.
Page 84 PISTON ASSEMBLY CAUTION NOTE: Whenever a piston, rings, or pin are out of Improper cleaning of the ring-grooves by the use of tolerance, they must be replaced. the wrong type of ring-groove cleaner will result in severe damage to the piston. Cleaning/Inspecting Piston Measuring Piston-Ring End Gap (Installed)
Page 85 NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. 2. The ring with the orientation mark (MTOP or TOP) should be installed in the second (middle) groove and the ring with the orientation mark (M or O) should be installed in the first (top) groove.
Page 86 3. Place the cylinder head on the Surface Plate cov- 2. Inspect the cylinder for pitting, scoring, scuffing, ered with #400 grit wet-or-dry sandpaper. Using warpage, and corrosion. If marks are found, repair light pressure, move the cylinder head in a figure the surface using a cylinder hone (see Inspecting eight motion.
Page 87 CC127D CC283D 2. Wash the cylinder in parts-cleaning solvent. 2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the sur- Measuring Camshaft Lobe Height face using a #320 grit ball hone.
Page 88 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 out of tolerance, replace the cylinder head. 3.
Page 89 Installing Top-Side Components A. Piston B. Cylinder 1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston. CC024D NOTE: The piston should be installed so the 4. Loosely install the two nuts which secure the cyl- arrow points toward the exhaust.
Page 90 7. Place a new head gasket into position on the cylin- 13. Install the rear cam chain tensioner guide into the der. Place the alignment pins into position; then cylinder head. Install the pivot cap screw and place the head assembly into position on the cylin- washer.
Page 91 CD463 ATV1027 16. Seat the cam sprocket onto the camshaft making CAUTION sure the alignment pin in the camshaft aligns with Care must be taken that the tab-washer is installed the smallest hole in the sprocket; then place the correctly to cover the alignment hole on the sprocket. camshaft/sprocket assembly onto the cylinder If the alignment pin falls out, severe engine damage ensuring the following.
Page 92 CD466 CD501 21. Place the C-ring into position in its groove in the NOTE: The adjuster shaft will be drawn into the cylinder head. tensioner as the adjuster screw is rotated clock- wise. The adjuster shaft tension will be released in step 25.
Page 93 CD471 CC003D 26. Loosen the four adjuster screw jam nuts; then 30. In a crisscross pattern starting from the center and loosen the four adjuster screws on the rocker arms working outward, tighten the cap screws (from in the valve cover. step 29) to 8.5 ft-lb.
Page 94 Removing Left-Side Components A. Outer Magneto Cover B. Water Pump C. Cover D. Rotor/Flywheel 1. Remove the four cap screws securing the outer magneto cover to the left-side cover; then remove CD923 6. Remove the two cap screws securing the water the outer magneto cover.
Page 95 12. Remove the snap ring securing the water pump drive gear; then remove the gear noting the direc- tion of the sides of the gear for installing purposes. Account for the drive gear alignment pin. CD939A CD944 13. Remove the snap ring securing the water pump driven gear;...
Page 96 15. Remove the gear shift cam plate; then remove the cam stopper and cam stopper spring. Account for two washers. CD949 NOTE: The sharp side of the snap ring should be facing outward. PR434A 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing);...
Page 97 CD139 PR433A PR447A CD934 4. In order on the crankshaft, install a washer, ring 6. Install the shift cam stopper, spring, and two wash- gear, key, and the magneto rotor. Secure with the ers; then coat the threads on the mounting stud nut.
Page 98 CD954A GZ253 CD927A GZ254 8. Lubricate the magneto cover gasket with fresh 13. Using a new gasket, install the speed sensor hous- engine oil; then place it into position on the two ing onto the crankcase and secure with two cap alignment pins.
Page 99 Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.  AT THIS POINT CD963 To service any one specific component, only limited disassembly of components may be necessary.
Page 100 PR393 A. Oil Pump Driven Gear D. One-Way Clutch 7. Remove the cap screws securing the clutch cover. B. Oil Pump Drive Gear E. Final Drive Carrier Bearing Note the location of the different-lengthed cap Housing C. Clutch Shoe Assembly screws for installing purposes.
Page 101 CF088A CC606 10. Remove the two cap screws securing the gear position switch; then remove the switch. Account for two neutral contact pins and two springs. CD987 CD997 11. Remove the nut (left-hand threads) securing the clutch shoe assembly (C). CD993 13.
Page 102 INSPECTING CENTRIFUGAL 14. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the CLUTCH SHOE direction of the sides of the gear for installing pur- poses. Account for a pin and a washer. 1.
Page 103 2. Install the secondary shaft bearing housing making sure the two alignment pins are properly posi- tioned. Tighten the cap screws to 28 ft-lb. CC446D DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley is a nonserviceable CD999 3. Install the oil pump onto the engine; then tighten component.
Page 104 CD991 PR410A 5. Grease the driven gear pin and insert it into the oil 7. Install the clutch cover alignment pins into the pump shaft; then install the driven gear (noting the crankcase, apply oil to the cover gasket, and install direction of the sides of the gear from removing).
Page 105 CF085A CD970 10. Apply grease to the outer edges of the clutch hous- 13. Place the driven pulley assembly into position and ing; then from inside the clutch cover, install the secure with the nut. Tighten to 80 ft-lb. clutch housing into the cover using a rubber mal- let.
Page 106 PR389 CD083 NOTE: The arrows on the V-belt should point for- ward. Center Crankcase Components 17. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft. Secure the drive face with a nut and (threads coated with red Loctite #271).
Page 107 2. Remove the reverse idler gear assembly (F). Account for all washers, shaft, bushing, and the gear. CC665 Disassembling CC668 Crankcase Half 3. Remove the shift shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes.
Page 108 11. Remove the cap screws securing the oil strainer cap; then remove the cap. 12. Remove the two cap screws securing the oil strainer; then remove the strainer. NOTE: Thoroughly clean any sealant from the oil strainer cap. CC675 7. Note the timing marks on the crank balancer assembly (B) gear and crankshaft (C) gear for assembling purposes;...
Page 109 1. Install a new bearing (A) onto the secondary driven shaft (B) making sure the bearing locating groove is directed away from the driven gear splines. MT008A 4. Install a new seal (F), output yoke (G), and nut (H) and tighten to 59 ft-lb. MT011A 2.
Page 110 Checking Backlash CRANKSHAFT ASSEMBLY 1. If removed, install the secondary drive/bevel gear NOTE: The crankshaft and connecting rod is a shaft into the crankcase; then tighten the nut to 59 non-serviceable assembly. If any component is ft-lb. out of specification, the assembly must be replaced.
Page 111 CC289D ATV-1017 3. Acceptable gap range must be within specifica- 2. Acceptable width range must be within specifica- tions. tions. Measuring Crankshaft (Runout) COUNTERSHAFT 1. Place the crankshaft on a set of V blocks. CAUTION When disassembling the countershaft, care must be 2.
Page 112 2. Install bearing and high driven gear; then install the left drive gear washer. From the right side: 1. Install driven gear washer, bushing, bearing and low driven gear. 2. Install lock washer, lock washer, washer and bush- ing. 3. Install bearing, reverse driven gear, washer, and the snap ring.
Page 113 CC675 CC668 6. Place a washer on each end of the countershaft 10. Install the front and rear secondary driven shaft assembly; then install the assembly. assemblies into the left side of the crankcase mak- ing sure the bearing locating pins are toward the top of the crankcase and the bearing C-ring is fully seated in the crankcase.
Page 114 Tighten to 20 ft-lb. Components. Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame; then slide the engine rearward as CD824 far as possible.
Page 115 CD793 CD809 8. Secure the engine ground wire to the engine with a 6. Secure the exhaust pipe to the engine with two cap cap screw. Tighten to 8 ft-lb. screws making sure the mounting brackets engage the frame grommets; then install the muffler and tighten the nuts securing the exhaust pipe to 20 ft-lb.
Page 116 16. Secure the crankcase vent hose to the air cleaner 20. Connect the hose to the fuel pump/fuel rail; then housing; then secure the inlet boot and carbure- connect the vacuum hose and secure with hose tor/throttle body to the air filter housing. clamps (650) or connect the gasline hose connec- tor to the fuel rail (EFI).
Page 117 1. Remove the seat and tool tray; then remove the negative battery cable. Table of Contents 2. Remove the front rack, gauge pod, footwells and (H2) footrests; then remove the front body panel (see Section 8). 3. Disconnect the IAT sensor connector; then loosen Removing Engine/Transmission......
Page 118 GZ094A GZ107 8. Disconnect the stator coil connector and the crank- NOTE: Using a suitable marker, mark the loca- shaft position sensor connector; then disconnect tions of any ties that are removed to relocate wir- the gear position switch connector. ing out of the way.
Page 119 GZ103B GZ099A 10. Remove the E-clips securing the shift linkage to 14. Remove the front and rear spark plug wires from the shift lever and shift shaft; then remove the shift the spark plugs; then disconnect the primary wire linkage. Account for two bushings and two flat connectors from the coils and remove the coils washers.
Page 120 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 121 GZ104 GZ123 21. Rotate the front driveshaft until the output yoke universal joint is in the vertical plane; then raise Top-Side Components the front of the engine/transmission until the front drive splines disengage from the differential. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
Page 122 3. Remove the cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the cam- shaft plug. Note the location of two alignment pins.
Page 123 GZ200 CC266D 5. Using an awl, rotate the C-ring in its groove until NOTE: Loop the chain over the cylinder head and it is out of the cylinder head; then remove the secure it to keep it from falling into the crankcase. C-ring.
Page 124 GZ151 GZ140A 12. Remove the two nuts securing the cylinder to the crankcase. GZ161 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 com- GZ141A pression stroke;...
Page 125 CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation.
Page 126 CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover. CC136D NOTE: The valve seals must be replaced. 3. Remove the valve springs; then invert the cylinder head and remove the valves.
Page 127 Servicing Valves/Valve Guides/Valve Seats 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. ATV1082A 3. Rotate the valve in the V blocks.
Page 128 Installing Valves NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston. 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve 4. Inspect the perimeter of each piston for signs of guide seal over each valve guide.
Page 129 CC280D CC127D 2. Measure the corresponding piston diameter at a Measuring Piston Pin (Outside point 15 mm (0.6 in.) above the piston skirt at a Diameter) and Piston-Pin Bore right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifica- 1.
Page 130 3. Place the cylinder head on the surface plate cov- ered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
Page 131 NOTE: To produce the proper 60° cross-hatch CAUTION pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not avail- Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to able, use a lightweight petroleum-based oil.
Page 132 ATV1013A CC145D 2. The lobe heights must not exceed minimum speci- 6. If clearance is excessive, measure the journals of fications. the camshaft. 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.
Page 133 CF060A GZ159 2. If damaged, the camshaft must be replaced. 3. Lubricate the inside wall of the cylinder; then using a ring compressor, 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 134 8. Apply a light coat of grease to the cylinder head cap screw threads and washers; then install the cap screws. GZ160A 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head GZ132B 9. Loosely install the five cylinder head nuts. D.
Page 135 A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the pis- ton). 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.
Page 136 17. Keeping tension on the opposite cam chain, rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loc- tite #271) and tighten to 10 ft-lb. Bend the tab to secure the cap screw.
Page 137 CAUTION If any of the above factors are not as stated go back to step 19 and carefully proceed. 22. Place tab-washer onto the sprocket making sure it covers the pin in the alignment hole. GZ193 ATV-1027 CAUTION Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket.
Page 138 27. Install the cylinder head plugs in the cylinder 30. Using a flat-blade screwdriver, rotate the adjuster heads with the open end facing downward and screw inside the tensioner counterclockwise until toward the inside. all tension is released; then install the cap screw into the end of the chain tensioner.
Page 139 GZ202 GZ208 33. Lubricate the camshaft journals and lobes with 38. If removed, install the spark plugs. Tighten engine oil; then place the valve cover into posi- securely. tion. Left-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
Page 140 GZ212A GZ216  AT THIS POINT NOTE: The puller has left-hand threads. To replace stator coils/crankshaft position sensor, see Section 5. 2. Remove the starter motor, starter driven gear (A), starter countershaft bushing (B), and starter coun- tershaft gear (C); then remove the starter gear shafts (D) noting that the longer shaft is nearest the starter.
Page 141 6. Remove the hose clamps from the water pump; then remove the coolant hoses from the water pump outlets and coolant pipes. GZ233A 9. Remove the nut (A) from the shift cam stopper bolt (B); then remove the cam stopper spring (C). Account for a flat washer (D).
Page 142 GZ243 GZ250 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 countershaft splines and install the trigger. Secure with a flat washer and outer snap ring. GZ235 12.
Page 143 GZ232 GZ259 5. If removed, install the shift cam stopper on the 7. Install the shift cam plate onto the shift cam shaft support; then with the flat washer in place, install and secure with the cap screw. Tighten to 8 ft-lb. the shift cam stopper assembly into the crankcase and tighten to 8 ft-lb.
Page 144 9. Apply grease to the lips of the shift shaft seal in the shifter housing; then using a new gasket, install the shifter housing and secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. GZ225 CAUTION Make sure the one-way starter clutch is properly engaged with the starter ring gear before installing and tightening the rotor/flywheel nut or damage to the...
Page 145 GZ212B GZ244B 2. Remove the nut securing the movable drive face; then remove the face. Account for a spacer and a Right-Side Components flat washer. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
Page 146 PR388 GZ247A 5. Remove the fixed drive face. NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. 6. Remove the cap screws securing the V-belt hous- ing to the crankcase; then remove the V-belt hous- 8.
Page 147 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 148 4. Apply grease to the outer edges of the clutch hous- ing; then from inside the clutch cover, install the Installing Right-Side clutch housing into the cover. Components 5. Lightly grease the clutch housing seal; then insert the left fixed drive spacer. 1.
Page 149 8. Making sure the alignment pins are correctly installed, place a bead of silicone sealant on the mating surfaces and install the V-belt housing. Secure with the cap screws tightened to 8 ft-lb. GZ065A 12. Place the V-belt into position on the driven pulley and over the front shaft.
Page 150 GZ264 components. The technician should use discretion and sound judgment. NOTE: Arctic Cat H2 engines are built with two different style cases and can easily be identified as Generation I or II by noting the speed sensor con- figuration on the left side.
Page 151 GZ321A GZ271 3. Remove the secondary drive assembly; then remove the secondary driven shaft assembly and set aside. Account for one locating ring. GZ272B Separating Crankcase GZ322B Halves (Gen. II) 1. Remove the oil strainer cap; then remove the oil strainer.
Page 152 GZ446 GZ269A 2. Remove the cap screws securing the lower crank- NOTE: Do not disassemble these assemblies case to the upper crankcase halves; then using a unless service is required. If disassembled, sec- rubber hammer, free the lower crankcase and ondary gear sets will have to be reset for backlash remove.
Page 153 3. Remove the water pump driven shaft (C). Account for the driven gear and drive pin. Disassembling Crankcase Half (Gen. I) NOTE: For steps 1-8, refer to illustration GZ298A. GZ304A 4. Remove the snap ring securing the oil pump driven gear (D) to the oil pump driveshaft; then remove the gear.
Page 154 Disassembling Crankcase Half (Gen. II) NOTE: For steps 1-8, refer to illustration GZ474A. GZ305 7. Remove the driveshaft (G); then remove the coun- tershaft assembly (with shift forks) (H). Account for three flat washers on the countershaft. GZ474A NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER.
Page 155 3. Remove the snap ring securing the water pump idler shaft (C) in the crankcase; then remove the shaft and bearings. GZ305 7. Remove the driveshaft (G); then remove the coun- tershaft assembly (with shift forks) (H). Account for two flat washers on the countershaft. GZ463A 4.
Page 156 3. If installing the existing shaft, start with the shims removed during disassembly or if installing a new Servicing Center shaft, start with approximately 1.0 mm shims at Crankcase Components point (D); then install the output driveshaft bearing (E) making sure the locating pin is directed toward the center of the shaft.
Page 157 4. Acceptable backlash range is 0.127-0.381 mm (0.005-0.015 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim.
Page 158 GZ358 GZ393B 5. Inspect the oil pump driveshaft and drive pin for OIL PUMP ASSEMBLY excessive wear or grooving. Replace as required. Disassembling and Inspecting 1. Remove the oil pump cover; then remove the gero- tor set, shaft, and pin (see appropriate Disassem- bling Crankcase Half in this section).
Page 159 GZ359 GZ360 2. Noting the reference dots on the gerotor set, sepa- 4. Place a new O-ring seal on the outside of the oil rate the inner rotor from the outer rotor and with pump cover. The oil pump assembly is now ready the reference dot directed toward the oil pump for assembly into the crankcase.
Page 160 Measuring Connecting Rod Measuring Crankshaft (Small End Deflection) (Web-to-Web) 1. Place the crankshaft on a set of V blocks and 1. Using a calipers, measure the distance from the mount a dial indicator and base on the surface outside edge of one web to the outside edge of the plate.
Page 161 GZ283A GZ314 2. Remove the drive gear; then remove the snap ring 5. Remove the reverse driven washer; then remove securing the reverse driven gear dog and bushing the low driven gear locking washer. to the countershaft. GZ320 GZ296 GZ319 GZ312 3.
Page 162 GZ316 GZ319B Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320B 3. Install the reverse driven bushing and bearing; then install the reverse driven gear. GZ317A GZ286A GZ318 2.
Page 163 GZ288A GZ283B 7. Install the two drive gear washers and the shift forks. The countershaft is now ready for installa- tion. Assembling Crankcase Half (Gen. I) 1. Install the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap GZ314 screws.
Page 164 3. Install the water pump drive gear, driveshaft, and drive pin; then install the countershaft into the crankcase and secure with a snap ring (flat-side away from the bearing). GZ332 GZ304A GZ333 7. Install the gear shift shaft into the crankcase mak- ing sure the flat washer is in place on the gear shift position switch end and the bearing assembly on the gear shift stop end.
Page 165 8. Place two flat washers on the drive gear end of the countershaft and one flat washer on the high Assembling Crankcase driven gear end; then with shift forks and shift fork Half shaft, install the countershaft assembly into the crankcase.
Page 166 4. Install the countershaft gear onto the countershaft and secure with a snap ring (flat-side away from the gear). GZ333 7. Install the gear shift shaft into the crankcase mak- ing sure the flat washer is in place on the right case end and the bearing assembly on the gear shift stop end.
Page 167 Joining Crankcase Halves (Gen. I) 1. Using rubber bands, support the connecting rods to align with the cylinder bores. GZ280B GZ340 2. Coat both sides with motor oil; then install the spacer washer on the crankshaft with the radius directed toward the crankshaft. GZ336 9.
Page 168 6. Install the locating ring in the crankcase assembly; then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly. GZ345B 4. Carefully join the crankcase halves by placing the left-side crankcase onto the assembled right side. Secure with the cap screws (eight left side and one right side).
Page 169 GZ265 GZ340 9. Carefully place the lower crankcase cover onto the 2. Coat both sides with motor oil; then install the joined crankcase halves; then secure with the cap spacer washer on the crankshaft with the radius screws. Tighten the 6 mm cap screws to 8 ft-lb and directed toward the crankshaft.
Page 170 GZ448A GZ342 7. Make sure the locating pins on the front and rear 5. Tighten the 6 mm cap screws to 8 ft-lb and the 8 bearings are correctly seated in the crankcase. mm cap screws to 20 ft-lb using the pattern shown and turning the shafts frequently to ensure there is 8.
Page 171 4. Align the rear output drive flange and the rear driveshaft yoke flange and install the cap screws. Tighten to 20 ft-lb. NOTE: Arctic Cat recommends that new gaskets 5. Align the engine with the mounting brackets and and O-rings be installed whenever servicing the install the through-bolts with flat washers;...
Page 172 11. Install the intake manifolds and tighten to 8 ft-lb; then install the throttle body and secure with the hose clamps. GZ069A GZ106 GZ368B 10. Install the front the rear exhaust pipes with new grafoil seals and tighten the retaining nuts to 20 ft-lb;...
Page 173 13. Install the shift linkage with bushings and secure with E-clips. 14. Connect the gasline hose connectors to the fuel rails; then install any nylon ties that were removed during disassembly. GZ013 16. Install the V-belt cooling duct and boots. Tighten securely.
Page 174 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Carburetor Specifications (400/650)......4-2 Carburetor Schematics (400/650) ......4-2 Carburetor (400/650)..........4-2 Electric Choke (400/650)......... 4-7 Electronic Fuel Injection (EFI) ......... 4-8 Throttle Cable Free-Play ........4-10 Engine RPM (Idle)..........4-11 Gas Tank ...............
Page 175 Fuel/Lubrication/ Carburetor Schematics Cooling (400/650) NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.
Page 176 PR154B CH015D 6. Remove the throttle cable from the actuator arm. 2. Remove the vacuum piston assembly from the car- buretor body. Account for a spring, spring seat, and the jet needle. PR162C 7. Loosen the outer jam nut securing the throttle cable to the carburetor body;...
Page 177 CC749 CC761A 7. Secure the needle jet holder with a wrench; then remove the main jet. 8. Remove the needle jet holder; then remove the needle jet, slow jet, and the starter jet. 9. Remove the pilot screw. Account for a spring, washer, and an O-ring.
Page 178 4. Dry all components with compressed air only making sure all holes, orifices, and channels are unobstructed. 5. Inspect the carburetor body for cracks, nicks, stripped threads, and any imperfections in the cast- ing. 6. Inspect the vacuum piston/diaphragm for cracks, imperfections in the casting, or cracks and tears in the rubber.
Page 179 CC749 CH015D 7. Place the U-ring into the pump housing. Position INSTALLING the spring and diaphragm assembly (lip toward the carburetor) onto the carburetor; then secure the assembly with the pump housing and three screws. 1. Connect the gas and vent hoses onto the carbure- Tighten securely.
Page 180 PR162C KC328A 5. Place the throttle actuator cover into position on 2. With the choke at room temperature (approxi- the carburetor; then secure with the screw. mately 70° F), measure plunger extension. Mea- surement (A) should be 18.6-19.1 mm. PR154B 6.
Page 181 2. Secure the choke with the screw and tighten securely; then connect the choke connector to the wiring harness. Electronic Fuel Injection (EFI) ! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be FI081B fuel leakage, there should be no welding, smoking, 5.
Page 182 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 183 2. Connect the three wiring connectors to the sen- sors; then install the air filter housing and connect all hoses. Tighten all clamps securely. GZ383A 6. Use tape to cover and seal the intake opening. CAUTION GZ094B Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine is turned over or started.
Page 184 2. Turn the adjuster until the throttle cable has proper free-play of 3-6 mm (1/8-1/4 in.) at the lever. Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leak- age, there should be no welding, smoking, open flames, etc., in the area.
Page 185 INSTALLING 1. Install the fuel level sensor/fuel pick-up assembly. 2. Place the gas tank into position in the frame; then install the cap screws. Tighten securely. 3. Connect the gas hose from the carburetor/throttle body; then connect the fuel gauge connector. 4.
Page 186 1. Remove the input and output hoses from the fit- 5. Remove the cap screws and nuts securing the radi- tings on the cooler. ator to the frame. 6. Disconnect the fan wiring from the main wiring CAUTION harness; then remove the radiator/fan assembly Elevate and secure the hoses to avoid oil spillage.
Page 187 4. Install the front bumper and front fender panel. D. If the thermostat does not open, it must be replaced. 5. Install the front rack. 3. Inspect all coolant hoses, connections, and clamps 6. Fill the cooling system with the recommended for deterioration, cracks, and wear.
Page 188 CC789 CC786A 2. Drain the oil from the engine/transmission. 3. Remove the four torx-head cap screws securing the front and rear fenders to the footrest; then remove the four cap screws securing the footrest to the frame. Remove the footrest. 4.
Page 189 Removing 2. Install the water pump assembly onto the engine aligning the flat drive on the water pump to the slot in the driveshaft. 1. Remove the coolant drain plug; then remove the radiator cap and drain the coolant into a suitable container.
Page 190 1. Turn the ignition switch ON and listen for a 4. Lift out the fuel pump assembly carefully tilting it momentary “whirring” sound of the pump build- forward to clear the voltage regulator; then guide ing pressure. If the sound is heard (10 seconds), no the pump and float lever through the opening in electrical checks are necessary.
Page 191 Vacuum Pulse Fuel Pump (400/650) The vacuum pulse fuel pump is not a serviceable com- ponent. If the pump fails, it must be replaced. TESTING ! WARNING FI460A B. Engage the tabs (C) of the fuel level sensor into Whenever any maintenance or inspection is made on the mounting slot (B) and press toward the bot- the fuel system during which there may be fuel leak- tom of the fuel pump to latch in place;...
Page 192 REMOVING 2. Remove the two machine screws and flange nuts securing the fuel pump to the electrical tray; then remove the pump. 1. Remove the seat; then remove the three clamps securing the gas hoses and vacuum hose and dis- INSTALLING connect the hoses.
Page 193 Troubleshooting (EFI) Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. TPS out of adjustment 1. Adjust TPS Problem: Medium or high speed impaired Condition Remedy 1.
Page 194 Speed Sensor ............5-10 Ignition Switch ............5-10 Handlebar Control Switches........5-11 Drive Select Switch ..........5-12 Front Drive Selector Actuator (400 TRV)....5-12 Front Drive/Differential Lock Actuator (H1/H2) ..5-13 Stator Coil (400 TRV/650) ........5-13 Stator Coil/Crankshaft Position (CKP) Sensor (EFI) ..............
Page 195 4000 ohms which show procedures for the complete servicing of Ignition Coil (primary) Less than 1 ohm (terminal to termi- the Arctic Cat ATV electrical system. Resistance nal) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) NOTE: Some photographs and illustrations used...
Page 196 ! WARNING ! WARNING An overheated battery could explode causing severe Anytime service is performed on a battery, the follow- injury or death. Always monitor charging times and ing must be observed: keep sparks, open flame, ciga- charge rates carefully. Stop charging if the battery rettes, or any other flame away.
Page 197 NOTE: Arctic Cat highly recommends all ATV bat- 2. Connect the red tester lead to the red/white wire or the positive connector; then connect the black tes- teries be connected to a maintenance charger dur- ter lead to ground. ing storage or any extended period of non-use.
Page 198 Oil Temperature and 1. Set the meter selector to the DC Voltage position. Cooling Fan Switches (400 TRV) 2. Connect the red tester lead to the orange wire; then connect the black tester lead to the red/blue wire. 1. Connect the meter leads (selector in the OHMS position) to the switch contacts.
Page 199 733-554C 733-554E 3. On the oil temperature switch when the oil temper- 3. On the coolant temperature switch when the oil ature reaches 160° C (320° F), the meter should temperature reaches 112-118° C (234-244° F), the read a closed circuit. meter should read a closed circuit.
Page 200 FUSES NOTE: To remove a fuse, compress the locking tabs on either side of the fuse case and lift out. 400 TRV FI501A 3. The meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of 2411-078 resistance, troubleshoot or replace the fan motor.
Page 201 2. On the H1/H2, connect the black tester lead to 2411-091 either primary connector; on the 400 TRV, connect CAUTION the black tester lead to the coil frame or to the pri- mary connector.
Page 202 1. Set the meter selector to the DC Voltage position; then disconnect the black/yellow and black pri- 4. Connect the MAP to the harness; then using Maxi- mary wires (400 TRV) or the terminal and ground Clips, connect the red tester lead to the wires (650) from the coil.
Page 203 Speed Sensor NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position. 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V);...
Page 204 RESISTANCE (HI Beam) NOTE: If the meter shows no battery voltage, troubleshoot the battery or the main wiring har- 1. Set the meter selector to the OHMS position. ness. 2. Connect the red tester lead to the yellow wire; then RESISTANCE connect the black tester lead to the gray wire.
Page 205 2. Connect the black tester lead to the negative bat- tery terminal. RESISTANCE (Reverse Override) 3. Connect the red tester lead to the red (400 TRV) or The connector is the four-prong white one next to the white (H1/H2) wire on the harness side of the con- steering post.
Page 206 (see Section 6). replace the actuator (see Section 6). Front Drive/Differential Stator Coil Lock Actuator (400 TRV/650) (H1/H2) VOLTAGE (AC Generator - Regulated Output) NOTE: With the engine stopped and the ignition switch in the ON position, a momentary “whirring”...
Page 207 VOLTAGE 3. The meter reading must be within specification. (AC Generator - No Load) RESISTANCE (Trigger Coil) The connector is a three-pin one in the harness coming CAUTION from the generator. Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. 1.
Page 208 AC VOLTAGE NOTE: The battery must be at full charge for these tests. Crankshaft Position Sensor 1. Set the meter selector to the AC Voltage position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the green wire. 3.
Page 209 CDI Unit 2. Select the DC Voltage position; then connect the (400 TRV/650) red tester lead to the positive battery post and the black tester lead to the negative battery post. The CDI is located beneath the seat near the battery.
Page 210 NOTE: The LO beam is the outside bulb, and the HI beam is the inside bulb. Ignition Timing 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to one wire; then con- The ignition timing cannot be adjusted; however, veri- nect the black tester lead to the other wire.
Page 211 ECU Error Code List Tilt Sensor NOTE: Each of the following numerical codes will have a two-letter prefix. A prefix of AC (Active (EFI) Code) or SC (Stored Code) will be displayed. Always correct and clear Active Codes before clearing Stored Codes. ! WARNING •...
Page 212 OUTPUT VOLTAGE NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up. NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected. 1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the rear frame.
Page 213 7. Connect the positive lead to the battery; then con- nect the negative lead. 8. Connect the main harness TPS connector to the TPS; then using MaxiClips, connect the black tes- ter lead to the black/green wire and the red tester lead to the green/black wire.
Page 214 INSTALLING/ADJUSTING 1. Place the TPS into position on the throttle body and secure with the two screws. Do not tighten at this time. 2. Connect the main harness to the TPS. 3. Locate the diagnostic connector under the seat next to the PDM; then install the test plug from Test Plug/Error Code List kit onto the connector.
Page 215 Problem: Spark plug electrodes overheat or burn Condition Remedy 1. Spark plug incorrect (too hot) 1. Replace plug 2. Engine overheats 2. Service cooling system 3. Spark plug loose 3. Tighten plug 4. Mixture too lean (400/650) 4. Adjust carburetor Problem: Magneto does not charge Condition Remedy...
Page 216: Table Of Contents
SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator/Electronic Differential Lock ..6-2 Front Differential ............6-3 Drive Axles ............6-16 Rear Gear Case ............ 6-21 Hub................ 6-23 Hydraulic Brake Caliper......... 6-25 Troubleshooting Drive System....... 6-28 Troubleshooting Brake System......
Page 217 NOTE: Special tools are available from the Arctic Cat Service Parts Department. Drive System Front Drive NOTE: Some photographs and illustrations used Actuator/Electronic in this section are used for clarity purposes only Differential Lock and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1.
Page 218 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 screws. AG927 4. Loosen but do not remove the mounting cap screw at the front of the actuator;...
Page 219 REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the drain plug and drain the gear lubricant into a drain pan;...
Page 220 AF628D AF610D 11. Pull the steering knuckle away from the axle. 15. Using a slide hammer, remove the front axles. KX151 AF899D 16. Remove the inner fender panels. 12. Support the axle to not allow it to drop or hang. 17.
Page 221 CD026 KX159 19. Remove the upper differential mounting cap Disassembling Input Shaft screws. NOTE: This procedure can be performed on a rear gear case; however, some components may vary from model to model. The technician should use discretion and sound judgment. 1.
Page 222 CD106 AF983 3. Using a boot-clamp pliers (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing. AF984 CD107 5. Using a seal removal tool, remove the input shaft seal.
Page 223 AF994 CD112 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft with High-Performance #2 Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess grease to freely escape. Slight pressure on the boot will be present during assembly.
Page 224 KX209 KX175 2. Using a T-40 torx wrench, remove the cap screws 5. Remove the left gear case bearing flange assembly securing the gear case cover. Account for and and account for a shim. Mark the shim as left-side. make note of the ID tag location for assembling purposes.
Page 225 KX181 CC878 7. Using the 48 mm Internal Hex Socket, remove the 9. Secure the pinion gear in a bearing puller; then lock collar securing the pinion gear assembly. remove the pinion bearing using a press. Account for a collar and a bearing. NOTE: On a front differential, the lock collar has right-hand threads.
Page 226 CC891 CC882 3. Note the following shim selections (shims are nominally 1.5 mm thick): CC883 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. 738-268C A. Cover Side - add value A on the gear case hous- ing to value B on the gear case cover;...
Page 227 CC890 CC893 4. Place a punch on the edge of the lock collar in the 7. Place the pinion housing assembly onto the gear oil gallery area; then using a hammer, stake the housing; then secure with the existing cap screws. lock collar to ensure that the collar will remain Tighten to 23 ft-lb.
Page 228 10. Apply a liberal amount of grease to the O-ring; then install it on the assembled cover assembly making sure to seat the O-ring down around the circumference of the bearing flange. 11. Making sure the O-ring is properly positioned on the differential/gear case cover assembly, install the cover with existing hardware.
Page 229 CC887 CC890 4. Place a punch on the edge of the lock collar in the Installing Needle Bearing oil gallery area; then using a hammer, stake the lock collar to ensure that the collar will remain 1. Apply red Loctite #271 to the outside of a new securely tightened.
Page 230 INSTALLING DIFFERENTIAL 1. Align the splined input yoke with the front output splines; then place the differential into position on the frame and install the cap screws, washers, and flex-lock nuts. Tighten to 38 ft-lb. Make sure the rubber boot is properly seated on the input yoke. CC900 3.
Page 231: Drive Axles
6. Secure the upper A-arms with cap screws and lock nuts. Tighten to 35 ft-lb. AF895D 9. Install the brake calipers and secure with new patch-lock cap screws tightened to 20 ft-lb. AF610D 7. Secure the lower shock eyelets with cap screws and lock nuts.
Page 232 CLEANING AND INSPECTING NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary. 1. Using a clean towel, wipe away any oil or grease from the axle components. KX041 5. Remove the two brake calipers (right side only). NOTE: Do not allow the brake calipers to hang from their cable/hose.
Page 233 CD021 CD752 3. Using a snap ring pliers, remove the snap ring NOTE: At this point if the outside boot is dam- securing the bearing ring to the shaft. Note the aged, continue with step 7. direction of the bearing for assembling purposes. 7.
Page 234 NOTE: Grease Pack contains 120 grams of NOTE: The boot is positioned correctly when the grease. The inside joint (double-offset) requires small end of the boot seats down into the recessed approximately 70-90 grams of grease and the out- groove. side (bell-type) requires approximately 35-55 grams.
Page 235 NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain “clipped” in place. 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. Secure the knuckle to the A-arm with a cap screw and a new lock nut.
Page 236: Rear Gear Case
5. Install the brake caliper on the steering knuckle using new “patch-lock” cap screws. Tighten to 20 ft-lb; then pump up the hand brake lever and engage the brake lever lock. 6. Tighten the hub hex nut (from step 4) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut.
Page 237 2. Remove the clutch pack from the clutch basket; then remove the snap ring securing the clutch bas- ket (A) to the input shaft (B) and remove the clutch basket. GZ182A 4. Remove the snap ring retaining the input bearing and using an appropriate bearing driver, press the bearing from the housing.
Page 238: Hub
GZ178A GZ179A 5. Inspect the clutch pack for signs of discoloration. 4. Install the clutch basket onto the input shaft and secure with the snap ring (flat side directed out- NOTE: The clutch pack is not a serviceable com- ward); then install the clutch pack into the basket. ponent.
Page 239 INSTALLING ! WARNING 1. Secure the brake disc to the hub with the four cap Make sure the ATV is solidly supported on the support screws coated with blue Loctite #243. Tighten to stand to avoid injury. 15 ft-lb. 2. Remove the cotter pin from the nut. 2.
Page 240: Hydraulic Brake Caliper
NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of control causing severe injury or death.
Page 241 CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2. Inspect the brake pads for damage and excessive wear. NOTE: For measuring brake pads, see Section 2. 3. Inspect the brake caliper housings for scoring in the piston bores, chipped seal ring grooves, or signs of corrosion or discoloration.
Page 242 PR711A PR239C 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the cali- per and install the inner brake pad; then install the outer pad. CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads.
Page 243: Troubleshooting Drive System
8. Fill the reservoir; then bleed the brake system (see 9. Install the wheel. Tighten to 40 ft-lb. Section 2). 10. Remove the ATV from the support stand and ver- ify brake operation. ! WARNING Never use brake fluid from an open container or reuse brake fluid.
Page 244 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 245: Table Of Contents
Tighten all front suspension nuts CAUTION to 35 ft-lb. Tighten rear suspension nuts (upper) to 35 ft-lb (400 TRV/H1); tighten rear suspension Additional support stands are necessary to support nuts (upper) to 50 ft-lb (H2). the rear axle when the shock absorbers are removed or damage may occur.
Page 246: Front A-Arms
6. Remove the cotter pin and slotted nut securing the CAUTION tie rod end to the knuckle; then remove the tie rod end from the knuckle. Do not tighten the nuts beyond the recommended specification or the shock eyelet or mount WILL be damaged.
Page 247 AF616D AF610D 3. Route the brake hose through the upper A-arm CLEANING AND INSPECTING shock 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 necessary.
Page 248: Rear A-Arms
NOTE: During assembly, new cotter pins should be installed. CD008 13. Install the wheel and tighten to 40 ft-lb. 14. Remove the ATV from the support stand. AF618D 8. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. Rear A-Arms REMOVING 1.
Page 249 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 (400 TRV/H1) or to 50 ft-lb (H2). 3. Tighten the hardware securing the A-arms to the frame mounts (from step 1) to 35 ft-lb (400 TRV/H1) or to 50 ft-lb (H2).
Page 250: Wheels And Tires
TIRE SIZE arrow” (if applicable) must indicate forward direc- tion of rotation). ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed in Section 1.
Page 251: Troubleshooting
NOTE: Be sure all tires are the specified size and NOTE: If pulling is noted, measure the circumfer- have identical tread pattern. ence of the front and rear tires on the pulling side. Compare the measurements with the tires on the opposite side.
Page 252 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-5 Steering Knuckles ........... 8-6 Measuring/Adjusting Toe-In........8-8 Front Rack ............... 8-9 Front Bumper Assembly .......... 8-9 Front Body Panel/Side Panels....... 8-10 Footrests ............... 8-13 Belly Panel ............
Page 253: Steering/Frame
Steering/Frame The following steering components should be inspected periodically to ensure safe and proper opera- tion. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. FI464A C. Steering post bearing assembly/bearing housing 2.
Page 254 FI467A CD760 5. Remove the storage compartment. 8. Using a suitable lift stand, raise the ATV enough to remove the front wheels. FI468 6. Remove the four cap screws securing the handle- CD685 bar caps and speedometer bracket to the steering 9.
Page 255 10. Remove two cap screws securing the lower steer- ing post bearing flange to the frame; then remove the steering post. AL600D 2. Place the upper steering post bearings into the housings; then position on the steering post and secure the housings to the frame with two cap AL600D screws.
Page 256: Handlebar Grip
6. Install the storage compartment box; then attach the storage compartment cover assembly by engaging the tabs into the slots and sliding rear- ward. Lock the storage compartment lid to hold the assembly in place. 7. Place the instrument pod into position; then secure with two reinstallable rivets and the ignition switch retaining ring.
Page 257: Steering Knuckles
2. Inspect the grip for deterioration. 3. If a grip is damaged, cut the grip lengthwise using a sharp knife or box cutter; the peel off the grip. INSTALLING NOTE: Before installing a grip, use contact spray or alcohol to clean the handlebar of glue residue, oil, or any other contaminant.
Page 258 PR287A PR290A 2. Install the knuckle to the upper and lower ball 5. Install the hub assembly onto the splines of the joints and secure with the two cap screws. Tighten shaft. to 35 ft-lb. 6. Secure the hub assembly with the nut. Tighten only until snug.
Page 259: Measuring/Adjusting Toe-In
NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (without an operator but with Arctic Cat approved accessories). 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each.
Page 260: Front Rack
AF778D 733-559A NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be Front Rack taken not to disturb the handlebar position. 8. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the REMOVING belly panel).
Page 261: Front Body Panel/Side Panels
CLEANING AND INSPECTING 2. Unlock the storage compartment lid; then slide the storage compartment cover assembly forward and lift off the storage compartment. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all bumper components with parts-cleaning solvent.
Page 262 FI464A FI470A 5. Remove the cap screws and lock nuts securing the 7. Remove the left and right footwells; then remove front rack to the frame; then remove the front rack. the shift knob. Remove the shift lever pivot axle Account for the grommets and bushings.
Page 263 CD681 CD765 9. Rotate the handlebar to the full-left position; then 2. Connect the headlight connectors to the appropri- lift and slide the panel to the rear and lift the rear ate headlights and the front accessory plug wires up to clear the handlebar. to the accessory plug.
Page 264: Footrests
CD779 FI466A 7. Install the instrument pod and ignition switch; then secure with two reinstallable rivets and the igni- tion switch retaining ring. 8. Set the storage compartment box into position; then install the storage compartment cover making sure the mounting tabs engage the slots. Slide rear- ward to secure and lock by engaging the lid lock.
Page 265: Belly Panel
CLEANING AND INSPECTING 2. Slide the muffler rearward to clear the mounting lugs and remove the muffler. NOTE: Whenever a part is worn excessively, INSPECTING MUFFLER cracked, or damaged in any way, replacement is necessary. NOTE: Whenever a part is worn excessively, 1.
Page 266: Taillight Assembly
CD687A CD691 4. Disconnect the battery (negative cable first); then 4. Place the battery into the battery box; then connect remove the battery. the battery (positive cable first) and secure with the battery cover. 5. Disconnect the taillight/brakelight; then remove the gas tank cap and lift off the rear body panel.
Page 267: Seat
1. Inspect wiring harness, three-prong connector, lens, base, cap screws, and socket for damage. 2. Inspect all wires for corroding, pinching, and cracking. 3. Inspect the bulb for wattage, voltage, and proper operation. INSTALLING 1. Place the assembly into position on the frame and secure with torx-head cap screws and any washers.
Page 268 Side Storage Box (TBX) REMOVING 1. Rotate the cargo box latch handle (located on the left and right sides between the cargo box and the rear tire) and fully raise the cargo box. 2. Pull the seat lock lever forward (located below CD045A the right side of the seat), raise the front end of 2.
Page 269 4. Inspect the cargo box gate latches for smooth operation. INSTALLING 1. Place the cargo box into position on the frame. Secure with cap screws and new lock nuts. Tighten securely. CD122  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.
Page 270: 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 271 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-3 Shift Lever ............... 9-4 Speedometer/Tachometer/LCD....... 9-4 Manual Table of Contents...
Page 272: Table Of Contents
4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the Hand Brake Lever/ pivot pin hole in the housing; then lay it aside Master Cylinder leaving the switch and wiring harness connected. Assembly NOTE: The master cylinder is a non-serviceable component;...
Page 273: Throttle Control
INSTALLING Throttle Control 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar. 2. Slide the grommet out of the lower half of the throttle control;...
Page 274: Shift Lever
INSTALLING 2. Remove two cap screws, two self-tapping screws, and three nylon ties securing the left-side splash panel and remove the panel. 1. Place the return spring into the throttle control; then place the bushing and actuator arm into posi- 3.

This manual is also suitable for:

650 h1 1000 h2

Arctic Cat 400 TRV Service Manual

Service Manual

Section 6 - Drive System

Suspension

Section 8 - Steering/Frame

Hand Brake Lever/

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Chapters

Troubleshooting

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Summary of Contents for Arctic Cat 400 TRV

Page 2: Table Of Contents

Page 5: Front Differential

Page 216: Table Of Contents

Page 231: Drive Axles

Page 236: Rear Gear Case

Page 238: Hub

Page 240: Hydraulic Brake Caliper

Page 243: Troubleshooting Drive System

Page 245: Table Of Contents

Page 246: Front A-Arms

Page 248: Rear A-Arms

Page 250: Wheels And Tires

Page 251: Troubleshooting

Page 253: Steering/Frame

Page 256: Handlebar Grip

Page 257: Steering Knuckles

Page 259: Measuring/Adjusting Toe-In

Page 260: Front Rack

Page 261: Front Body Panel/Side Panels

Page 264: Footrests

Page 265: Belly Panel

Page 266: Taillight Assembly

Page 267: Seat

Page 270: Troubleshooting

Page 272: Table Of Contents

Page 273: Throttle Control

Page 274: Shift Lever

This manual is also suitable for:

Arctic Cat 400 TRV Service Manual

Service Manual

Section 6 - Drive System

Suspension

Section 8 - Steering/Frame

Hand Brake Lever/

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Arctic Cat 400 TRV

Summary of Contents for Arctic Cat 400 TRV

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Table of Contents