Arctic Cat ROV 2013 Service Manual
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Arctic Cat ROV 2013 Service Manual

Arctic Cat ROV 2013 Service Manual

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  • Page 2 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat 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 fol- low the directive because it deals with the possibility of serious personal injury or even death.

  • Page 4: Table Of Contents

    Table of Contents General Information ............2 Electrical Connections............77 General Specifications............2 Accessory Receptacle/Connector ........77 Torque Specifications ............3 Brakelight Switch............... 77 Torque Conversions (ft-lb/N-m)..........4 Engine Coolant Temperature (ECT) Sensor ..... 78 Break-In Procedure .............4 Fan Motor ................78 Gasoline - Oil - Lubricant.............4 Power Distribution Module (PDM) ........

  • Page 5: General Information

    Gasoline (recommended) 87 Octane Regular (1st/2nd) Unleaded Piston Ring Groove Width (1st/2nd) 1.202-1.204 mm Engine Oil (recommended) Arctic Cat ACX All Weather (oil) 2.01-2.03 mm Synthetic Piston Ring Thickness (1st/2nd) 1.970-1.990 mm Front Differential/Rear Drive Lubricant SAE Approved 80W-90 Hyp- Piston Pin Bore (max) 23.0 mm...

  • Page 6: Torque Specifications

    DRIVE TRAIN COMPONENTS Torque Specifications Torque Part Part Bolted To ft-lb N-m Rear Differential/Gear Case Frame Drive Coupler (Front) Front Drive Flange  NOTE: Torque specifications have the following tol- Front Engine Mounting Bracket Frame erances: Rear Engine Mounting Bracket Frame Engine Mounting Through-Bolt Frame Torque (ft-lb) Tolerance...

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    CAUTION 20.4 54.4 88.4 122.4 21.8 55.8 89.8 123.8 Do not use white gas. Only Arctic Cat approved gaso- line additives should be used. 23.1 57.1 91.1 125.1 24.5 58.5 92.5 126.5 RECOMMENDED ENGINE/ 25.8...

  • Page 8: Genuine Parts

    RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE Preparation For Storage LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 CAUTION hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat vehicle front differential Prior to storing the vehicle, it must be properly serviced and rear drive.
  • Page 9 2. Clean the engine. Remove the cloth from the exhaust CAUTION system. Connect the positive battery cable first; then the nega- 3. Check all control wires and cables for signs of wear tive. or fraying. Replace if necessary. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, 4.

  • Page 10: Periodic Maintenance

    * 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 and strainer inspection interval can be increased to every 1,000 miles or every year.

  • Page 11: Lubrication Points

    VALVE/TAPPET CLEARANCE  NOTE: Foam Filter Cleaner and Foam Filter Oil are Intake 0.1016 mm (0.004 in.) available from Arctic Cat. Exhaust 0.1524 mm (0.006 in.) 4. Dry the element. 5. Put the element in a plastic bag; then pour in air filter oil and work the element.

  • Page 12: Testing Engine Compression

    NOTE: The seat, seat back, and seat base must be removed for this procedure. 1. Remove the high tension lead from the spark plug. 2. Using compressed air, blow any debris from around the spark plug. ! WARNING Always wear safety glasses when using compressed air.

  • Page 13: Muffler/Spark Arrester

    ATV-0051 PR498 CAUTION Before removing the spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug. Adjust the gap to 0.5-0.6 mm (0.019-0.024 in.). PR499 2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen.

  • Page 14: Front Differential - Rear Drive Lubricant

    PR078A GZ461A 3. Using the Oil Filter Wrench and a ratchet handle (or CAUTION a socket or box-end wrench), remove the old oil fil- ter. Do not over-fill the engine with oil. Always make sure that the oil level is not above the upper mark. NOTE: Clean up any excess oil after removing 10.

  • Page 15: Driveshaft/Coupling

    Front Differential Headlight/Taillight- Brakelight HEADLIGHT  NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the 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 16: Shift Lever

    4. Make vertical marks which intersect the horizontal 2. Make sure the shift lever is in park; then remove the marks on the aiming surface directly in front of the E-clip securing the cable end to the shift arm stud. headlights.
  • Page 17 CHECKING/BLEEDING The hydraulic brake system has been filled and bled at the factory. To check and/or bleed a hydraulic brake sys- tem, use the following procedure. 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the res- ervoir is not above the MIN, add DOT 4 brake fluid.

  • Page 18: Burnishing Brake Pads

    BRAKE DISC Using a micrometer, measure the thickness of the brake disc in the contact surface. If thickness is 0.125 in. or less, the disc must be replaced. To replace the brake disc, see the Drive System section – Hub. Burnishing Brake Pads Brake pads must be burnished to achieve full braking effectiveness.
  • Page 19 INSTALLING 1. Place the V-belt into position on the driven pulley and over the front shaft. CD963 GZ085 NOTE: The arrows on the V-belt should point forward. 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a washer and nut (coated with red Loctite #271).

  • Page 20: Troubleshooting Brake System

    Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Brake fluid leaking 2. Repair - replace hydraulic system 3. Master cylinder/brake cylinder seal worn 3. Replace seal(s) Problem: Brake pedal travel excessive Condition Remedy 1.

  • Page 21: Engine/Transmission

    SPECIAL TOOLS Engine/Transmission A number of special tools must be available to the techni- cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description. This section has been organized into sub-sections which show a progression for the complete servicing of the Arc- Description tic Cat ROV engine/transmission.

  • Page 22: Troubleshooting

    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. Replace guides 3. Valves mistimed 3. Retime engine 4. Piston rings worn - broken 4.
  • Page 23 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 excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 24: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service/replace right- HDX138A side cover oil seals, front output joint oil seal, rear out- 6.
  • Page 25 8. Loosen the clamp securing the throttle body to the intake manifold boot; then remove the throttle body and set aside. 9. From the left side, disconnect the ECT sensor con- nector, speed sensor connector, and spark plug cap. HDX149A 12.

  • Page 26: Top-Side Components

    16. Disconnect the oil cooler lines and plug them to prevent oil spillage. 17. Remove the nuts from the rear engine mounts; then remove the front through-bolt. HDX154 14. Remove the two exhaust springs at the muffler; then remove the exhaust pipe. Account for a grafoil seal in the cylinder head and a grafoil seal at the muffler.

  • Page 27: Removing Top-Side Components

    Removing Top-Side Components A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspec- tion plug; then using an appropriate wrench, rotate the crankshaft to top-dead-center of the compres- sion stroke. CD206 1. Remove the two tappet covers. CD211A 3.
  • Page 28 CC012D CC014D 5. Bend the washer tabs down and remove the two cap NOTE: Loop the chain over the cylinder and screws securing the sprocket to the camshaft; then secure it to keep it from falling into the crankcase. drop the sprocket off the camshaft. 8.
  • Page 29 9. Remove the cylinder head from the cylinder, remove the gasket, and account for four O-rings and two alignment pins; then remove the cam chain guide. CC023D 12. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins.

  • Page 30: Servicing Top-Side Components

    CAUTION Servicing Top-Side When removing the cylinder, be sure to support the pis- Components ton to prevent damage to the crankcase and piston. 13. Using an awl, remove the piston-pin circlips. 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,...
  • Page 31 1. Using a valve spring compressor, compress the valve 2. Acceptable diameter range must be within specifica- springs and remove the valve cotters. Account for an tions. upper spring retainer. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of each valve face.
  • Page 32 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. ATV-1011A CAUTION 4. Place a spring retainer over the valve springs; then...
  • Page 33 Measuring Piston Pin (Outside 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within speci- fications, the piston pin must be replaced.
  • Page 34 Installing Piston Rings CYLINDER/CYLINDER HEAD ASSEMBLY 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the NOTE: If the cylinder/cylinder head cannot be expander making sure the expander ends do not trued, they must be replaced as an assembly.
  • Page 35 Honing Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements.
  • Page 36 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. CC005D 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3.

  • Page 37: Installing Top-Side Components

    Installing Top-Side Components A. Piston B. Cylinder 1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston. NOTE: The piston should be installed so the arrow points toward the exhaust. CC287D NOTE: If the journals are worn, replace the cam- shaft;...
  • Page 38 7. Place the head gasket into position on the cylinder. Place the alignment pins with four O-rings into posi- tion; then place the head assembly into position on the cylinder. CC024D 4. Loosely install the two nuts which secure the cylin- der to the crankcase.
  • Page 39 CD461 CD463 13. With the alignment pin installed in the camshaft, 15. Seat the cam sprocket onto the camshaft making sure loosely place the cam sprocket (with the recessed the alignment pin in the camshaft aligns with the side facing the cam shaft lobes) onto the camshaft. smallest hole in the sprocket;...
  • Page 40 ATV1027 CD466 20. Place the C-ring into position in its groove in the cyl- CAUTION inder head. Care must be taken that the tab-washer is installed cor- rectly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.
  • Page 41 CD501 CD471 25. Loosen the four adjuster screw jam nuts; then loosen NOTE: The adjuster shaft will be drawn into the the four adjuster screws on the rocker arms in the tensioner as the adjuster screw is rotated clock- valve cover. wise.

  • Page 42: Left-Side Components

    Removing Left-Side Components A. Water Pump B. Side Cover C. Rotor/Flywheel 1. Remove the four screws securing the outer magneto cover to the side cover; then remove the cover. 2. Remove the flange nut securing the spacer to the CC003D crankshaft;...
  • Page 43 10. Using Magneto Rotor Remover Set with appropriate crankshaft protector, remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly and washer. CD920A  NOTE: It may be necessary to use a small two-jaw puller to remove the trigger.

  • Page 44: Servicing Left-Side Components

    CD140 PR430A 12. Remove the snap ring securing the water pump drive 15. Remove the gear shift cam plate; then remove the gear; then remove the gear noting the direction of the shift cam stopper and cam stopper spring. Account sides of the gear for installing purposes.
  • Page 45 FI569 FI576A 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING FI572 1. Support the starter clutch gear in a press making sure REPLACING STARTER CLUTCH to support the hub around the entire circumference;...

  • Page 46: Installing Left-Side Components

    FI580 FI595A INSPECTING STATOR/MAGNETO COVER ASSEMBLY Installing Left-Side Components 1. Inspect the stator for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws. NOTE: Plug the oil passage in the crankcase 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in housing prior to installing the drive gear/driven bearing bores.
  • Page 47 CD949 CD139 NOTE: The sharp side of the snap ring should be facing outward. 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing); then secure with the snap ring.
  • Page 48 CD935A CD927A 8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins. Make sure the outer shift shaft washer is in place. CD934 6. Install the shift cam stopper, spring, and two wash- ers;...

  • Page 49: Right-Side Components

    Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT  To service any one specific component, only limited dis- GZ253 assembly of components may be necessary.
  • Page 50 CD963 PR393 6. Remove the cap screws securing the clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Using a rubber mallet, carefully remove the cover. Account for two align- ment pins. CD966A 3. Remove the nut securing the fixed driven assembly; then remove the assembly.
  • Page 51 CF088A 9. Remove the nut (left-hand threads) securing the A. Oil Pump Driven Gear D. One-Way Clutch clutch shoe assembly (C). (Green Dot MUST Show) B. Oil Pump Drive Gear E. Final Drive Carrier Bearing C. Clutch Shoe Assembly Housing PR398C 7.

  • Page 52: Servicing Right-Side Components

    CD993 CD895A 11. Using an impact driver, remove the Allen-head 13. Remove the cap screws securing the oil pump; then screws securing the final drive carrier bearing hous- remove the pump. ing (E); then remove the housing and account for two alignment pins.

  • Page 53: Installing Right-Side Components

    Installing Right-Side Components 1. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the cap screws to 28 ft-lb. ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2.
  • Page 54 CD991 PR410A 4. Grease the driven gear pin and insert it into the oil 6. Install the clutch cover alignment pins into the crank- pump shaft; then install the driven gear (noting the case, apply oil to the cover gasket, and install the direction of the sides of the gear from removing).
  • Page 55 CF086 CD970 9. Apply grease to the outer edges of the clutch hous- 12. Place the driven pulley assembly into position and ing; then from inside the clutch cover, install the secure with the nut. Using Spanner Wrench, tighten clutch housing into the cover using a rubber mallet. to 80 ft-lb.

  • Page 56: Center Crankcase Components

    Separating Crankcase Halves 1. Remove the left-side cap screws securing the crank- case halves. Note the location of the different- lengthed cap screws. 2. Remove the right-side cap screws securing the crankcase halves. Note the location of the different- lengthed cap screws. 3.
  • Page 57 NOTE: To aid in installing, it is recommended the assemblies are kept together and IN ORDER. 1. Remove the secondary driven shaft assembly (A) noting the location of the bearing locating pins. Account for the bearing C-ring. CC674 NOTE: Do not disassemble the countershaft assembly unless necessary.

  • Page 58: Servicing Center Crankcase Components

    Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY OUTPUT DRIVE GEARS Initial Set-Up CD832B NOTE: If the secondary output driven shaft is 9. Remove the snap ring securing the water pump replaced or disassembled, the initial set-up must driven gear shaft.
  • Page 59 MT012 MT016A 6. To adjust tooth contact, use the following chart to correctly shim the driven shaft. Tooth Contact Shim Correction Contact at Top Increase Shim Thickness Contact at Root Decrease Shim Thickness 7. After correct tooth contact is established, proceed to Checking Backlash in this sub-section.
  • Page 60 Correcting Backlash 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim. 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim.
  • Page 61 2. Remove the drive gear; then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft. ATV-1017 2. Acceptable width range must be within specifica- tions. COUNTERSHAFT GZ296 GZ312 3. Remove the reverse driven gear dog. GZ281A CAUTION When disassembling the countershaft, care must be...
  • Page 62 Assembling 5. Remove the reverse driven washer; then remove the low driven gear locking washer. 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320 GZ317A GZ319 GZ318 2.

  • Page 63: Assembling Crankcase Half

    3. Install the reverse driven bushing and bearing; then install the reverse driven gear. GZ313A GZ286A GZ312 6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), GZ287 bushing (C), bearing (D), high/low driven gear (E), 4.
  • Page 64 MT014 CD832B 2. Apply a liberal amount of engine oil to the crank- NOTE: It will be necessary to rotate the crank bal- shaft bearing. Using a propane torch, heat the bear- ancer until the counterweight is facing away from ing until the oil begins to smoke;...

  • Page 65: Joining Crankcase Halves

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

  • Page 66: Installing Engine/Transmission

    Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components. Installing Engine/ Transmission NOTE: Arctic Cat recommends new gaskets and O- rings be installed whenever servicing the vehicle. HDX153A 1. Using a suitable lifting sling and engine hoist,...
  • Page 67 HDX135A HDX135A 8. Install the starter cable to the starter motor, secure with the nut, and tighten securely; then secure the engine/harness ground wires to the engine with a cap screw and tighten to 8 ft-lb. HDX137A 11. Install the throttle body into the intake manifold boot and secure with the clamp.
  • Page 68 HDX031A HDX136A 14. Connect the gasline hose to the throttle body making 16. Pour the recommended amount of oil and coolant sure the gasline hose connector fully engages and into the engine and radiator; then loosen the cool- locks onto the fuel rail. ant bleed screw to allow trapped air to escape.

  • Page 69: Fuel/Lubrication/Cooling

    2. Remove the seat, seat back, and seat base; then dis- connect the battery. Fuel/Lubrication/Cooling 3. Remove the air inlet boot between the air filter and throttle body; then disconnect the MAP sensor con- nector (A), fuel injector connector (B), and ISC con- SPECIAL TOOLS nector (C).

  • Page 70: Gas Tank

    FI092A PR698A 6. Loosen the clamp securing the throttle body to the 3. Remove the outer cap screw securing the front tank intake manifold boot and remove the throttle body hold-down; then swing the hold-down to the left. assembly. 7. Use tape to cover and seal the intake opening. CAUTION Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine...
  • Page 71 5. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap. PR699A 2. Swing the front hold-down to the right into position and install the cap screw and nut. Do not tighten at this time. PR699A 6.

  • Page 72: Gas/Vent Hoses

    7. Position the floorboard into the vehicle and secure with the appropriate hardware; then install the seat base, seat back, and seat. Gas/Vent Hoses Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the vent hoses.

  • Page 73: 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, open the bleed screw on the thermostat housing to allow air to bleed from the cooling system.
  • Page 74 PR183A PR184A 5. Remove the two shoulder bolts and nuts securing the 2. Connect the upper and lower coolant hoses to the radiator to the frame; then disconnect the upper and radiator and secure with the appropriate hose clamps; lower coolant hoses. then connect the cooling fan wire connector to the main harness.

  • Page 75: Thermostat

    2. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. Thermostat REMOVING 1. Drain approximately one quart of coolant from the REMOVING cooling system. 2. Remove the two cap screws securing the thermostat 1. Remove the radiator (see Radiator in this section). housing to the cylinder head.

  • Page 76: Electric Fuel Pump/Fuel Level Sensor

    PR132 HDX158B 5. Remove the two cap screws securing the water pump NOTE: While the cooling system is being filled, to the engine; then remove the water pump. 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.
  • Page 77 INSPECTING 2. Disconnect the gasline hose from the fuel rail; then install a suitable pressure gauge. AT THIS POINT ! WARNING If the pump has failed earlier test and must be replaced, Gasoline may be under pressure. Place an absorbant proceed to INSTALLING.

  • Page 78: Troubleshooting

    INSTALLING 2. Connect the gasline hose to the fuel pump pipe and secure with the hose clamp; then connect the electri- 1. Place the fuel pump assembly into the gas tank with cal plug to the main harness. a new gasket aligning the match marks; then secure 3.

  • Page 79: Electrical System

    RPM operation, short trips, and high amperage accessory usage are also reasons for battery discharge. Maintenance Charging  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...

  • Page 80: Rpm Limiter

    Charging NOTE: For absolute accuracy, all tests should be made at room temperature of 68° F.  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Switches 1.

  • Page 81: Engine Coolant Temperature (Ect) Sensor

    NOTE: The ignition switch must be in the ON 3. When the lever is depressed, the meter must show less than 1 ohm. position. NOTE: If the meter shows more than 1 ohm of VOLTAGE (Wiring Harness resistance, replace the switch. Connector) 1.

  • Page 82: Power Distribution Module (Pdm)

    NOTE: Make sure the fuses are returned to their proper position according to amperage. Refer to the amperage listed under each fuse on the power distribution module. 2. Set the meter selector to the DC Voltage position. 3. Connect the black tester lead to ground. 4.

  • Page 83: Manifold Absolute Pressure (Map) Sensor

    3. Turn the ignition switch to the ON position. The meter must show battery voltage. Manifold Absolute Pressure (MAP) Sensor  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this sec- tion).

  • Page 84: Electronic Power Steering (Eps)

    3. Turn the ignition switch to the ON position. Electronic Power 4. The meter must show approximately 6 DC volts. Steering (EPS) 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead pin (S). 6.

  • Page 85: Ignition Switch

    VOLTAGE Fault Code Possible Cause Recovery Method Description 1. Set the meter selector to the DC Voltage position. C1315 Engine RPM Broken CAN wires in the EPS will auto-recover main harness. when engine RPM 2. Connect the red meter lead to the red wire; then con- signal returns to nor- nect the black meter lead to ground.

  • Page 86: Reverse Override Switch

    2. Using an ohmmeter, the following readings must be 2. Depress the reverse override switch. The meter observed. showing should not change from step 1. 3. Select 4WD on the drive select switch. The meter must show approximately 5 DC volts. 4.

  • Page 87: Stator Coil/Crankshaft Position (Ckp) Sensor

    3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14- 15.5 DC volts. CAUTION Do not run the engine at high RPM for more than 10 sec- onds. NOTE: If voltage is lower than specified, test AC Generator - No Load.

  • Page 88: Starter Motor

    RESISTANCE NOTE: The ignition switch must be in the ON posi- (Crankshaft Position Sensor) tion, and the shift lever in the NEUTRAL position. 1. Set the meter selector to the OHMS position. 1. Set the meter selector to the DC Voltage position. 2.

  • Page 89: Electronic Control Module (Ecm)

     NOTE: Make sure the ignition switch is in the ON position, transmission in neutral, and parking brake Regulator/Rectifier set. 3. Depress the starter button while observing the multi- meter. The multimeter should drop to 0 volts and a  NOTE: Preliminary checks may be performed on this “click”...

  • Page 90: Taillight-Brakelight

    If ignition timing cannot be verified, the rotor may be dam- aged, the key may be sheared, the trigger coil bracket may Taillight-Brakelight be bent or damaged, or the ECM may be faulty. VOLTAGE (Taillight) EFI Diagnostic System NOTE: Perform this test at the socket end of the taillight-brakelight harness (pigtail).
  • Page 91 Examples of Static checks: Battery voltage, fuel gauge/ 2. High Temperature indicator (on @ 230 degrees F.) sensor, and TPS (0% @ closed throttle, 95-100% @ 3. Thermostat opening @ approximately 180 degrees F, WOT). indicated by a momentary drop or pause in the rising temperature reading.
  • Page 92 MAP (bArO) Diagnostic Mode 1. CKP (crankshaft position) sensor to ECM 2. ECM (CAN) signal to gauge (tachometer) 3. ECM (CAN) signal to EPS Speed (SPd) Diagnostic Mode EFI006 Display: MAP in millibars (1013 millibar = 29.92 in. mercury). DTC: P0107, P0108 EFI008 Usage: Verify barometric pressure signal correct.
  • Page 93 Battery (bAtt) Diagnostic Mode 3. Battery voltage with electrical accessories operating, engine idling (13.5 VDC or greater). 4. Battery voltage starter cranking (10.5-11.5 VDC). DIAGNOSTIC TROUBLE CODES (DTC) If an EFI or related chassis component fails or an out-of- tolerance signal is detected by the ECM, a diagnostic trouble code (DTC) will be generated in the ECM and displayed on the LCD.
  • Page 94 Gauge DTC Wrench Icon Status ECM PIN Description Tilt Sensor Circuit High C0063 Tilt Sensor Circuit Low/SG/Open C0064 Fuel Sender Open C1400 17 (Gauge) Fuel Sender High/SP C1401 17 (Gauge) Fuel Sender Low/SG C1402 17 (Gauge) MAP Sensor Circuit Low/SG/Open P0107 MAP Sensor Circuit High/SP P0108...

  • Page 95: Tilt Sensor

    OUTPUT VOLTAGE Tilt Sensor NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected. ! WARNING 1. Connect the three-wire plug to the sensor; then Incorrect installation of the tilt sensor could cause sud- remove the right-side mounting screw securing the sensor to the rear frame.

  • Page 96: Throttle Position Sensor (Tps)

    NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up. PR538A NOTE: If the meter does not read as specified, check for poor connections at the ECM or open/ CD705A broken wires in the wiring harness. CAUTION Throttle Position Sensor (TPS)
  • Page 97 2. Connect the TPS Multi-Analyzer Harness connector #8 to the TPS; then connect the harness to the TPS Analyzer Tool. PR546A 8. Select the DC Voltage position on the meter and turn the ignition switch to the ON position. The meter should read approximately 0.6 DC volts with the FI672 throttle closed and approximately 4.0 DC volts with...

  • Page 98: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.

  • Page 99: Drive System

    REMOVING Drive System 1. Select LOCK on the drive select switch; then discon- nect the connector on the actuator harness. 2. Using a T-30 torx wrench, remove the mounting cap GENERAL INFORMATION screw from the driveshaft side of the actuator. All gear cases are tagged beneath a cover bolt.

  • Page 100: Front Differential

     NOTE: Make sure to properly align the differential 7. Secure the wiring harness to the frame with a nylon cable tie. lock actuator lever with the hole in the differential lock plunger. Front Differential REMOVING 1. Remove the belly panel; then place the vehicle on jack stands adjusted high enough to allow working from the underside of the vehicle.
  • Page 101 PR264A PR222 7. Disconnect the front drive actuator connector from 10. Support the axle to not allow it to drop or hang. the main harness. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. 11.
  • Page 102 PR205A GC015 14. Remove the upper differential mounting cap screw. Account for a lock nut and two washers. CD106 3. Remove the snap rings from the input shaft; then remove the input shaft from the pinion housing. CD016 15. Free the differential assembly from the frame mount- ings;...
  • Page 103 5. Remove the snap ring securing the input shaft bear- ing; then place the pinion housing in a press and remove the bearing. GC012 GC011 GC011 2. Install the input shaft seal making sure it is fully seated in the edge of the housing. AF984 GC014 3.
  • Page 104 GC009A GC015 5. Place the pinion housing with new gasket onto the 2. Using a T-40 torx wrench, remove the cap screws differential housing; then secure with existing cap securing the differential cover. Account for and make screws. Tighten to 23 ft-lb. note of the ID tag location for assembling purposes.
  • Page 105 KX175 KX181 5. Remove the left differential bearing flange assembly Disassembling Pinion Gear and account for a shim. Mark the shim as left-side. 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
  • Page 106 CC879 CC884 4. Remove any reusable parts from the gear case hous- 3. Using a propane torch, heat the gear case housing to ing; then discard the housing and lock collar. approximately 200° F; then install the pinion assem- bly. Assembling Pinion Gear 4.
  • Page 107  NOTE: All bearings must be installed in the gear case and the pinion properly installed before pro- ceeding. Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly.
  • Page 108 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 estab- lished, the gear case can be assembled (see Assem- bling Differential Assembly in this sub-section).
  • Page 109 3. Assemble the fork and sliding collar into the cover 6. Install the shift fork shaft w/spring into the housing assembly; then install the left bearing flange/bearing making sure the shaft O-ring is positioned to the assembly and seat firmly into the cover. inside.
  • Page 110 INSTALLING DIFFERENTIAL 1. Place the differential assembly into position in the frame; then install the top mounting cap screw, two washers, and lock nut. Do not tighten at this time. 2. Install the lower differential mounting cap screw, washers, and lock nut. Note the correct location for the washers. CD110 Removing/Installing Axle Seal NOTE: This procedure can be performed on a...

  • Page 111: Drive Axles

    PR193 PR256 8. Secure the lower shock eyelets with cap screws and 12. Install the wheels and tighten in 20 ft-lb increments lock nuts. Tighten to 20 ft-lb. to 80 ft-lb. 13. Remove the vehicle from the support stand. 14. Install the belly panel. Drive Axles REMOVING REAR DRIVE AXLE 1.
  • Page 112 PR221 PR729B 5. Remove the cap screw and lock nut securing the REMOVING FRONT DRIVE AXLE knuckle to the upper A-arm. Discard the lock nut.  NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING AXLES ...
  • Page 113 CD020 CD022 2. Wipe away excess grease to access the retaining ring. 5. Inspect the splines of the shaft, the bearing ring, and Using an awl or circlip pliers, remove the circlip. the housing for damage.  NOTE: If any damage is apparent to the splines, the bearing ring, and/or the housing, the drive axle must be replaced as an assembly.
  • Page 114 ATV-1052 CD024  NOTE: The grease pack contains 120 grams of ASSEMBLING AXLES grease. The inside joint (double-offset) requires 1. Install the inner boot with the small clamp making approximately 70-90 grams of grease and the outside sure the ends of the clamp are positioned correctly. (bell-type) requires approximately 35-55 grams.
  • Page 115 CD022 CD024 8. Inspect the axle components for correct positioning CAUTION of the four clamps. Also, inspect the boots for being The bearing ring must go onto the shaft with the side correctly positioned on the shaft. without splines facing toward the small clamp of the INSTALLING REAR DRIVE AXLE inner boot or severe damage will result.

  • Page 116: Rear Gear Case

    5. Install the wheel. Tighten in 20 ft-lb increments to 80 ft-lb. Rear Gear Case 6. Remove the vehicle from the support stand and release the parking brake. REMOVING INSTALLING FRONT DRIVE AXLE  NOTE: Release the cargo box latch and allow the 1.
  • Page 117  NOTE: For servicing bearings or seals, see Front Differential in this section. Installing/Shimming  NOTE: Ring gear clearance must be adjusted prior to selecting shim for the thrust button. 1. Install the thrust button with shim into the gear case cover and tighten securely (left-hand threads).

  • Page 118: Hub

    Cleaning and Inspecting 1. Wash all parts in parts cleaning solvent and dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air. 2. Clean all gasket material and sealant from mating surfaces. 3. Inspect bearings, shafts, and housing for excessive wear, cracks, or discoloration.
  • Page 119 NOTE: During assembly, new cotter pins should 4. Inspect the hub for pits, cracks, loose studs, or spline wear. be installed. REPLACING WHEEL STUDS 1. Secure the hub in a suitable holding fixture and remove the brake disc (if applicable). 2.

  • Page 120: Hydraulic Brake Caliper

    3. Install the hub assembly onto the axle; then place the transmission in park. Hydraulic Brake Caliper ! WARNING Arctic Cat recommends only authorized Arctic Cat ROV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 121 NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. PR713A PR237A PR715 ! WARNING Make sure to hold the towel firmly in place or the piston PR238 could be ejected from the housing causing injury. 5.
  • Page 122 PR719C PR715 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. PR717A 2. Press the piston into the caliper housing using hand pressure only.
  • Page 123 PR239 PR338 6. Place the brake caliper assembly into position and secure with new “patch-lock” cap screws. Tighten the caliper to 20 ft-lb. 7. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb. 8.

  • Page 124: Universal Joints

    Universal Joints REMOVING NOTE: The universal joints can be accessed by removing the belly panel. To remove the belly panel, see Belly Panel in the Steering/Frame/Con- trols section. 1. Support the vehicle on suitable jack stands elevated high enough to allow working from the underside of PR375 the vehicle.
  • Page 125 PR367C PR374 3. Install the retainer in the bearing cup; then remove INSTALLING the yoke from the separator tool. 1. Remove the bearing cups from the universal joint;  NOTE: Repeat steps 2-3 for the opposite-side bear- then insert the joint into the yoke and install one ing cup.

  • Page 126: Troubleshooting

    Troubleshooting Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft 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 127: Suspension

    Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods bent, pitted, or damaged. B. Rubber damper cracked, broken, or missing. C. Shock absorber body damaged, punctured, or leaking. AF730D D. Shock absorber eyelets broken, bent, or cracked. CLEANING AND INSPECTING E.
  • Page 128 DISASSEMBLING ! WARNING Always wear latex or rubber gloves when servicing a shock absorber with shock oil. 1. Remove the valve cap; then bleed the air from the air chamber. FS144 5. Using a pick, remove the air valve ball from the nitrogen bladder.
  • Page 129 8. Using a 5/64-in. Allen-wrench, remove the set screw from the bearing cap. FS151 12. Drain the oil from the shock body into a suitable con- tainer. FS148 9. Using a magnet held against the Allen-wrench, 13. Using an appropriate floating piston removal tool, remove the bleed ball.
  • Page 130 FS154 FS157 2. Carefully install the floating piston into the shock 5. Lubricate the O-ring on the underside of the end cap body until it is below the threads. with shock oil. FS155 FS158 3. Using an appropriate location tool, install the float- 6.
  • Page 131 8. Using Spanner Wrench, tighten the bearing cap. 10. Charge the shock with nitrogen to 200 psi. FS161 FS164 11. Using a 3/16-in. Allen-wrench, tighten the  NOTE: When tightening the bearing cap, note air nitrogen bladder. and excess oil being bled from the hole in the cap. FS165 FS150A 12.
  • Page 132 18. Thread the air chamber into the end cap until hand- tight. FS167 15. Lubricate the seal on the air chamber with Fox Float Fluid. FS171  NOTE: Prior to installing the air chamber, make sure the end cap O-ring is properly positioned in the chamber.

  • Page 133: Front A-Arms

    21. Install the valve cap. CD007 5. Remove the hub assembly. FS174 22. Install the spring using an appropriate spring com- 6. Remove the cotter pin and slotted nut securing the tie pressor and secure with the retaining ring. rod end to the knuckle; then remove the tie rod end from the knuckle.
  • Page 134 AF610D AF616D 11. Remove the snap ring from the ball joint; then remove 2. Install the A-arm assemblies into the frame mounts the ball joint from the A-arm. and secure with the cap screws. Only finger-tighten at this time. AF616D AF610D CLEANING AND INSPECTING 3.

  • Page 135: Rear A-Arms

    AF628D PR377B 7. Install the tie rod end and secure with the nut (coated 11. Secure the hub nut (from step 9) to the shaft/axle. with red Loctite #271). Tighten to 30 ft-lb; then install Tighten to 200 ft-lb. a new cotter pin and spread the pin to secure the nut. 12.
  • Page 136 5. Remove the cap screws and lock nut securing the 2. Slide the knuckle onto the drive axle and into position shock absorber to the frame and lower A-arm; then on the A-arms; then secure the knuckle to the A-arms remove the shock absorber.

  • Page 137: Wheels And Tires

    ! WARNING Use only Arctic Cat approved tires when replacing tires. 1. Clean the wheels and hubs with parts-cleaning sol- Failure to do so could result in unstable vehicle opera- vent.

  • Page 138: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2. Spring(s) weak 2. Replace spring(s) 3. Shock absorber damaged 3. Replace shock absorber 4. Rear shock absorbers too soft 4. Check and adjust air pressure in shocks Problem: Suspension too stiff Condition Remedy...

  • Page 139: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full- right capability. C. Steering sector mounting bolts tight. PR760A D. Ball joints not worn, cracked, or damaged. 4.
  • Page 140 PR765A PR776A 7. Remove the steering shaft housing and shaft from the NOTE: Alignment need only be approximate as steering support and intermediate shaft; then remove final alignment is not possible until the EPS is the intermediate shaft from the EPS input shaft. engaged with the coupler.
  • Page 141 PR764B PR780 9. Install the cap screw in the intermediate shaft coupler 4. Using an appropriate crow-foot and backing wrench, and tighten to 31 ft-lb; then tighten the cap screw remove the tie rod assembly. (from step 6) to 11 ft-lb. NOTE: Tie rods come as a complete assembly.

  • Page 142: Steering Assembly

    NOTE: Always attach the crow-foot to the torque wrench with the open end 90° to the torque wrench handle to ensure accurate torque application. PR301 3. Remove the EPS cradle bracket; then remove the cap screws securing the steering rack assembly to the rack bracket and remove from the left side.

  • Page 143: Steering Wheel

    NOTE: If the hole in the steering shaft does not align with the slots in the castle nut, tighten the nut slightly until the next slot aligns with the hole. PR773A 3. Place the tie rod ends into the knuckles and secure with the castle nuts (coated with red Loctite #271).

  • Page 144: Intermediate Steering Shaft Assembly

    NOTE: Any time steering components are disas- sembled, all connecting components should be Intermediate Steering marked for proper alignment during assembling. Shaft Assembly INSPECTING 1. Inspect the steering wheel shaft for excessive wear. AT THIS POINT 2. Check for worn splines, cracks, or damaged threads. Before beginning this procedure, the upper steering shaft 3.

  • Page 145: Steering Knuckles

    6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. 7. Remove the two cap screws securing the ball joints in the knuckle. PR764B 4. Install the cap screw in the intermediate shaft coupler and tighten to 31 ft-lb;...
  • Page 146 NOTE: During assembling, new cotter pins should be installed. 4. Apply a small amount of grease to the hub splines. PR292A PR290A 5. Install the hub assembly onto the splines of the shaft. PR289 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws.

  • Page 147: Accelerator Pedal

    PR260 PR342C NOTE: If the hole in the axle shaft does not align INSTALLING with the slots in the castle nut, tighten the nut until the hole and slots align. Align the mounting holes with the holes in the splash panel and secure with the two torx-head screws and nuts;...

  • Page 148: Shift Cable

    INSTALLING 3. Tilt the cargo box back and remove the E-clip from the shift arm on the transmission; then loosen the 1. Install the shift axle supports onto the shift lever; adjuster nut on the shift cable housing and remove then secure the axle supports to the frame with four the shift cable from the transmission.

  • Page 149: Lcd Gauge/Indicator Lights

    7. Shift the transmission through all positions making sure the gear position icons indicate the appropriate gears selected and that the Park Indicator illuminates only when fully in Park. (See Shift Lever - Checking Shift Cable Adjustment in the Periodic Maintenance section).

  • Page 150: Checking/Adjusting Front Wheel Alignment

    CAUTION Checking/Adjusting Front Wheel Alignment Always use a wrench to hold the tie rod ends when loos- ening or tightening the jam nuts or damage to the boots could occur. 2. Turn the left-side and right-side tie rods in equal NOTE: All measurements and adjustments must increments to achieve the proper toe-out;...

  • Page 151: Hood

    Hood REMOVING 1. Open the hood; then disconnect the four headlight connectors and remove two nylon ties. PR332 3. Connect the four headlight connectors; then secure the wires with two new nylon ties. PR328A 2. Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame;...

  • Page 152: Floor

    5. From the opposite side of the vehicle, repeat step 3; then lift the rear of the floor up and lift the floor out Floor of the vehicle. CLEANING AND INSPECTING REMOVING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- 1.

  • Page 153: Belly Panel

    INSTALLING INSPECTING MUFFLER 1. Place the dash into position and connect the park/ NOTE: Whenever a part is worn excessively, cracked, seat belt indicator light, dash harness, and gauge or damaged in any way, replacement is necessary. connector. 1. Inspect muffler externally for cracks, holes, and 2.

  • Page 154: Taillight Assembly

    3. Lower the cargo box; then remove the four cap screws (from step 2). Taillight Assembly 4. With the help of an assistant or an adequate lift, remove the cargo box from the vehicle. Account for four pivot housings. REMOVING CLEANING AND INSPECTING 1.

  • Page 155: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Steering shaft binding 2. Lubricate/replace steering shaft 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

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