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 Click on the Red text to go. Foreword Section General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame Controls/Indicators 10. Aids for Maintenance 11. Troubleshooting...
Page 3: Table Of Contents
SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (400/400 TBX/400 TRV - Automatic Transmission) ........1-2 General Specifications (400 - Manual Transmission)........ 1-3 General Specifications (500 - Manual Transmission)........ 1-4 General Specifications (500/500 TBX/500 TRV - Automatic Transmission) ........1-5 General Specifications (650 H1) ...............
Page 4: General Specifications (400/400 Tbx/400 Trv - Automatic Transmission)
General Specifications* MISCELLANY (400/400 TBX/400 TRV - Automatic Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - VP Transmission) 24.6 L (6.5 U.S. gal.) - FIS 20.8 L (5.5 U.S. gal.) - TBX/ Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP...
Page 5: General Specifications (400 - Manual Transmission)
General Specifications* MISCELLANY (400 - Manual Transmission) Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - 24.6 L (6.5 U.S. gal.) - FIS Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP CARBURETOR Rear Drive Capacity 275 ml (9.3 fl oz) - VP*** 250 ml (8.5 fl oz) - FIS**...
Page 6: General Specifications (500 - Manual Transmission)
General Specifications* MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) (500 - Manual Transmission) Coolant Capacity 2.9 L (3.0 U.S. qt) 275 ml (9.3 fl oz)** Differential Capacity Rear Drive Capacity 250 ml (8.5 fl oz)*** CARBURETOR Engine Oil Capacity 3.4 L (3.5 U.S.
Page 7: General Specifications (500/500 Tbx/500 Trv - Automatic Transmission)
General Specifications* (500/500 TBX/500 TRV - CHASSIS Automatic Transmission) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 CARBURETOR Tire Inflation Pressure 0.35 kg/cm² (5 psi) Type Keihin CVK36 MISCELLANY Main Jet Gas Tank Capacity (rated)
Page 8: General Specifications (650 H1)
General Specifications* (650 H1) CHASSIS CARBURETOR Brake Type Hydraulic w/Brake Lever Type Keihin CVK40 Lock and Auxiliary Brake Main Jet Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 Slow Jet Tire Inflation Pressure 0.35 kg/cm² (5 psi) Pilot Screw Setting (turns) MISCELLANY Jet Needle...
Page 9: General Specifications (650 V-Twin)
General Specifications* (650 V-Twin) CARBURETOR CHASSIS Type Keihin CVKR-D32 (2) Brake Type Hydraulic w/Brake Lever Main Jet 122 - Standard Lock and Auxiliary Brake 118 - California Tire Size Front - 26 x 8-12 Slow Jet Rear - 26 x 11-12 Pilot Screw Setting (turns) 2 1/4 (front) Tire Inflation Pressure...
Page 10: Break-In Procedure
! CAUTION accelerations and variations in driving speeds con- Do not use white gas. Only Arctic Cat approved tribute to good engine break-in. gasoline additives should be used. During the break-in period (or whenever the brake...
Page 11: Genuine Parts
(p/n 0436-007) or an equivalent gear lube which is Genuine Parts SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives. When replacement of parts is necessary, use only genuine Arctic Cat ATV parts.
Page 12: Preparation After Storage
4. Change the engine/transmission oil and filter. ter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage Preserver (p/n 5. On liquid cooled models, check the coolant level 0636-177), rapidly inject the preserver into the and add properly mixed coolant as necessary.
Page 13 Lubrication Points............ 2-3 (400/500 Manual Transmission) ......2-18 Battery..............2-3 Tires ..............2-19 Fuses ..............2-4 Steering Components ........... 2-19 Air Cleaner/Filter (400 VP) ........2-5 Driveshaft/Coupling ..........2-19 Air Cleaner/Filter ............. 2-7 Suspension/Shock Absorbers/Bushings ....2-20 Valve/Tappet Clearance Nuts/Bolts/Cap Screws.......... 2-20 (Feeler Gauge Procedure) ........
Page 14: Periodic Maintenance Chart
A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate D = Drain R = Replace Chart Initial Service Every Every 3 Every 6 Every After Break-In Every Month or Months Months Year or Item (First Mo or Every or Every or Every...
Page 15: Lubrication Points
Lubrication Points It is advisable to lubricate certain components peri- odically to ensure free movement. Apply light oil to the components using the following list as reference. A. Throttle Lever Pivot/Cable Ends B. Brake Lever Pivot/Cable Ends CHARGTIM C. Auxiliary Brake Cable Ends D.
Page 16: Fuses
0411-828 secured to the frame. 400 FIS Manual/500 Manual 8. Connect cables to the proper terminals: positive cable to the positive terminal (+) and negative cable to the negative terminal (-). Connect the negative cable last.
Page 17: Air Cleaner/Filter
Always replace a blown fuse with a fuse of the same type and rating. Air Cleaner/Filter (400 VP) The air filter inside the air filter housing must be kept clean to provide good engine power and gas mileage. If the ATV is used under normal condi- CD087 tions, service the filter at the intervals specified.
Page 18 CHECKING/DRAINING DRAIN TUBE 4. Loosen the clamp securing the air cleaner to the front boot; then loosen the clamp securing the 1. Periodically check the drain tube for gasoline or air cleaner to the rear filter sleeve. oil accumulation. If noticed, remove the drain tube cap from beneath the front housing, drain 5.
Page 19 6. Place the air cleaner cover into position and secure with the retaining clips. CD710B 2. On the 400 FIS, remove the storage compart- ment assembly by elevating the rear of the com- AL645D partment, moving it rearward, and lifting it off.
Page 20 NOTE: Foam Filter Cleaner (p/n 0436-194) and Foam Filter Oil (p/n 0436-195) are available from CF145B Arctic Cat. 7. Dry the filter. Next Back Back to TOC...
Page 21: Valve/Tappet Clearance (Feeler Gauge Procedure)
NOTE: On the 400 VP, the seat assembly, side panels, and gas tank must be removed for this pro- cedure. 1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components).
Page 22: Valve/Tappet Clearance (Valve Adjuster Procedure)
Clearance (650 V-Twin) in this section. To check and adjust valve/tappet clearance, use the following procedure. NOTE: On the 400 VP, the seat assembly, side panels, and gas tank must be removed for this pro- cedure. NOTE: On the TBX/500/650 H1, the seat, storage...
Page 23: Valve/Tappet Clearance (650 V-Twin - Valve Adjuster Procedure)
ATV2057B ATV2058B 4. Using a feeler gauge, check each valve/tappet 6. Install the timing inspection plug. clearance. If clearance is not within specifica- 7. Place the four tappet covers into position. tions, loosen jam nut (B) and rotate the tappet Tighten the cap screws securely.
Page 24: Testing Engine Compression
(five to 10 compression strokes). 0.07 mm (0.003 in.) per mark. NOTE: For the 400, the compression should be 8. While holding the adjuster dial at the proper within a range of 95-115 psi in the full-open throttle clearance setting, tighten the jam nut securely position.
Page 25: Spark Plug
Spark Plug Muffler/Spark Arrester A light brown insulator indicates that a plug is cor- The muffler has a spark arrester which must be peri- rect. A white or dark insulator indicates that the odically cleaned. At the intervals shown in the Peri- engine may need to be serviced or the carburetor odic Maintenance Chart, clean the spark arrester may need to be adjusted.
Page 26: Gas/Vent Hoses
Gas/Vent Hoses Adjusting Choke Cable (650 V-Twin) Replace the gas hose every two years. Damage from To adjust the choke cable for proper free-play, fol- aging may not always be visible. Do not bend or low this procedure. obstruct the routing of the carburetor vent hose. Make certain that the vent hose is securely con- 1.
Page 27: Engine/Transmission Oil - Filter - Strainer
RPM. 733-441A 4. On the 400/500, remove the oil filter plug from the filter mounting boss (located on the front Engine/Transmission side of the transmission case) and allow the fil- Oil - Filter - Strainer ter to drain completely.
Page 28 12. Install the oil level stick until the threads touch engine case. NOTE: For servicing the oil strainer on the 650 NOTE: On the 400 auto/500 auto/650 H1, the oil V-Twin, see Center Crankcase Components in Sec- level stick should not be threaded into the case for tion 3.
Page 29: Front Differential/Rear Drive Lubricant
Front Differential/Rear Drive Lubricant Check and change the lubricant according to the Periodic Maintenance Chart. When changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, use the following proce- dure. 1. On FIS models, remove the rear drive filler CC163D plug;...
Page 30: Adjusting Clutch (400/500 Manual Transmission)
Adjusting Clutch (400/500 Manual Transmission) To adjust the clutch, use the following procedure. 1. Using an impact driver, remove the screws securing the cover and remove the cover.
Page 31: Tires
Tires TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed. Do not under any circumstances substitute tires of a different type or size. ! WARNING CC037D 3. Rotate adjustment screw #1 counterclockwise Always use the size and type of tires specified. until it stops.
Page 32: Suspension/Shock Absorbers/Bushings
B. Coupling cracked, damaged, or worn. 2. Using the Arctic Cat Engine Tachometer (p/n 0644-275), start the engine and run at the rec- ommended RPM; ignition timing should be the recommended degrees BTDC. Suspension/Shock Absorbers/Bushings IGNITION TIMING MODEL TIMING/RPM 10° BTDC @ 1500 The following suspension system components 10°...
Page 33: Switches
TAILLIGHT-BRAKELIGHT 4. Make vertical marks which intersect the hori- zontal marks on the aiming surface directly in To replace the taillight-brakelight bulb, use the fol- front of the headlights. lowing procedure. 5. Switch on the lights. Make sure the HIGH beam 1.
Page 34: Reverse Shift Lever
To adjust, proceed to Adjusting Shift Lever. CF150A ADJUSTING SHIFT LEVER 400/500 Automatic Transmission/650 H1 1. Handle 2. Push Clip 3. Shift Plate 4. Stamped Nut 5. Lever 6.
Page 35 400/500 Manual Transmission 1. Handle 2. Push Clip 3. Shift Plate 4. Stamped Nut 5. Lever 6. Spring 7. Axle 8. Nut 9. O-Ring 10. Axle 11. O-Ring 12. Cap Screw 13. Washer 14. Nut 15. Rod End 16. Linkage 17.
Page 36: Frame/Welds/Racks
AF941A CD716A C. Using two open-end wrenches, remove lock C. Verify correct shifting operation; then install nut (B) securing the shift rod to the upper the seat. shift axle. Discard the lock nut. NOTE: Never reuse a lock nut. Once a lock nut Frame/Welds/Racks has been removed, it must be replaced with a new lock nut.
Page 37 0739-542 CD713 2. Making sure the brake pedal is fully released CHECKING/BLEEDING and against the stop, check that the holes in the push-rod actuator align with the hole in the The hydraulic brake systems have been filled and pedal lever. bled at the factory.
Page 38 NOTE: During the bleeding procedure, watch the reservoir sight glass very closely to make sure there is always a sufficient amount of brake fluid. When the sight glass changes from dark to light, refill the reservoir before the bleeding procedure is continued.
Page 39: Burnishing Brake Pads
3. If thickness of either brake pad is less than 3.2 mm (0.125 in.), the brake pads must be replaced. Burnishing Brake Pads NOTE: The brake pads should be replaced as a set. Brake pads (both hydraulic and auxiliary) must be 4.
Page 40: Checking/Replacing V-Belt (400/500/650 H1)
After operating the ATV for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary. Checking/Replacing V-Belt (400/500/650 H1) CC547 4. Remove the V-belt. REMOVING 1. Remove the right-side footrest (see Section 8).
Page 41: Checking/Replacing V-Belt (650 V-Twin)
5. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to specifications. CC549 2. Place the V-belt into position on the driven clutch and over the front shaft.
Page 42 NOTE: Before removing the belt, note the mark- ings (A) (or mark the belt using tape or marker) in order to reinstall in the same direction as previ- ously installed. 6. Lift the belt (B) off the driven pulley (C). KX230 3.
Page 43 KX232 NOTE: Make sure the belt is at the top of the KX246A driven pulley (A) before checking belt deflection. 4. Disassemble the driven pulley. See Section 3, Servicing Right-Side Components, steps 1-5. 5. Remove the shims (A) and measure the shim pack thickness.
Page 44: Adjusting Differential Lock Cable
10. Connect the actuator lead and the Belt Failure Detection Switch lead; then install the air duct and secure with the clamps. Adjusting Differential Lock Cable If the differential or differential lock system has been serviced, the differential lock cable should be checked and/or adjusted for proper free-play.
Page 45 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications (400 - Automatic Transmission)..3-3 Specifications (400 - Manual Transmission).... 3-4 Specifications (500 - Automatic Transmission)..3-6 Specifications (500 - Manual Transmission).... 3-7 Specifications (650 H1) ........... 3-9 Specifications (650 V-Twin) ........3-10 400 (Manual Transmission) Table of Contents ..........
Page 46: Engine/Transmission
To service top-side, left-side, and right-side compo- nents, the engine/transmission does not have to be removed from the frame. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing engine/transmission.
Page 47: Specifications (400 - Automatic Transmission)
CYLINDER, PISTON, AND RINGS Specifications* Piston Skirt/Cylinder 0.060-0.073 mm Clearance (0.0024-0.0029 in.) (400 - Automatic Transmission) Cylinder Bore 82.000-82.015 mm (3.2283-3.2289 in.) Piston Diameter 81.930-81.945 mm 15 mm (0.6 in.) from Skirt End (3.2256-3.2262 in.) VALVES AND GUIDES Piston Ring (1st Ring) 8.9 mm...
Page 48: Specifications (400 - Manual Transmission)
CYLINDER, PISTON, AND RINGS Specifications* Piston Skirt/Cylinder 0.060-0.073 mm Clearance (0.0024-0.0029 in.) (400 - Manual Transmission) Cylinder Bore 82.000-82.015 mm (3.2283-3.2289 in.) Piston Diameter 81.930-81.945 mm 15 mm (0.6 in.) from Skirt End (3.2256-3.2262 in.) VALVES AND GUIDES Piston Ring (1st Ring) 8.9 mm...
Page 49 CLUTCH Clutch Release Screw 1/8 turn back Drive Plate (fiber) Thick- (min) 2.62 mm (0.103 in.) ness Drive Plate (fiber) Tab 13.25-13.95 mm (0.52-0.55 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.) Clutch Spring Length (min) 33.7 mm (1.33 in.) Clutch Wheel 140.0-140.2 mm Inside Diameter...
Page 50: Specifications (500 - Automatic Transmission)
CYLINDER, PISTON, AND RINGS Specifications* Piston Skirt/Cylinder 0.030-0.040 mm Clearance (0.0011-0.0015 in.) (500 - Automatic Transmission) Cylinder Bore 87.500-87.515 mm (3.4448-3.4454 in.) Piston Diameter 87.465-87.480 mm 15 mm (0.6 in.) from Skirt End (3.4435-3.4440 in.) VALVES AND GUIDES Piston Ring (1st Ring) 9.0 mm Valve Face Diameter...
Page 51: Specifications (500 - Manual Transmission)
CYLINDER, PISTON, AND RINGS Specifications* Piston Skirt/Cylinder 0.030-0.040 mm Clearance (0.0011-0.0015 in.) (500 - Manual Transmission) Cylinder Bore 87.500-87.515 mm (3.4448-3.4454 in.) Piston Diameter 87.465-87.480 mm 15 mm (0.6 in.) from Skirt End (3.4435-3.4440 in.) VALVES AND GUIDES Piston Ring (1st Ring) 9.0 mm Valve Face Diameter...
Page 52 CLUTCH Clutch Release Screw 1/4-1/2 turn back Drive Plate (fiber) (min) 2.82 mm (0.1110 in.) Thickness Drive Plate (fiber) Tab (min) 2.9 mm (0.507 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.) Clutch Spring Length (min) 35.6 mm (1.40 in.) Clutch Wheel 140.0-140.2 mm Inside Diameter...
Page 53: Specifications (650 H1)
CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance 0.045 mm (0.0018 in.) Specifications* Cylinder Bore 98 mm (3.858 in.) Piston Diameter 97.948-97.962 mm (650 H1) 15 mm (0.6 in.) from Skirt End (3.856-3.857 in.) Piston Ring (1st ring) 12.5 mm (0.492 in.) Free End Gap (2nd ring) 12.5 mm (0.492 in.)
Page 54: Specifications (650 V-Twin)
CYLINDER, PISTON, AND RINGS Specifications* Piston Skirt/Cylinder Clear- 0.030-0.040 mm ance (0.0011-0.0015 in.) (650 V-Twin) Cylinder Bore 79.994-80.006 mm (3.149-3.150 in.) Piston Diameter 15 mm 79.949-79.964 mm (0.6 in.) from Skirt End (3.147-3.148 in.) Cylinder Trueness (max) 0.05 mm (0.002 in.) VALVES AND GUIDES Piston Ring End Gap - (1st)
Page 55 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery Table of Contents vent hose; then remove the battery. (400 - Manual Transmission) ! CAUTION Battery acid is harmful if it contacts eyes, skin, or Removing Engine/Transmission......3-11 clothing.
Page 56 NOTE: On FIS models, the air cleaner intake duct must be removed prior to removing the air cleaner housing. 11. Remove the exhaust springs at the juncture in front of the muffler; then slide the muffler rearward off the mounting lugs. CC934 14.
Page 57 20. Disconnect the battery ground (negative) cable from the crankcase cover; then disconnect the positive cable from the starter motor. CC119D 17. Detach the carburetor from the intake boot; then secure the carburetor assembly away from the engine. AR600D CC120D AR604D 21.
Page 58: Top-Side Components
CF164A CF176 22. Loosen the clamp on the crankcase breather vent 24. By sliding the rear of the engine out first, remove hose; then disconnect the hose and remove it. the engine/transmission from the left side of the frame. 23. Remove engine/transmission mounting fasteners in the following sequence:...
Page 59: Removing Top-Side Components
MD1354A 3. Loosen the cap screw on the end of the cam chain NOTE: Arctic Cat recommends the use of new tensioner; then remove the two Allen-head cap gaskets, lock nuts, and seals and lubricating all screws securing the tensioner assembly and i n t e r n a l c o m p o n e n t s w h e n s e r v i c i n g t h e engine/transmission.
Page 60 MD1251 MD1131 5. Bend the washer tabs and remove the two cap 7. Note the timing marks for installing purposes; then screw securing the sprocket to the camshaft. drop the sprocket off the camshaft. While holding the chain, slide the sprocket and camshaft out of the cylinder head.
Page 61 C. Cylinder D. Piston NOTE: Steps 1-11 in the preceding sub-section must precede this procedure. 12. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half. Account for the washers. MD1167 10. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins.
Page 62: Left-Side Components
AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. 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 MD1213 components.
Page 63 CC943 CC945 4. Remove the gear shift stopper (located above the hi/low shift shaft). Account for the washer, spring, and stopper. CC946 NOTE: Inspect the inside of the left-side cover for any shaft washers and spacers that may have come off with the cover. Make sure they are CC944 returned to their respective shafts.
Page 64 Driven Gear Drive Gears #1 & #2 Idler Gear Shift Fork with Pin Shift Shaft Starter Idler Gear #1 Starter Idler Gear #2 Starter Clutch Gear Assembly Rotor/Flywheel CC948B 6. Remove the nut securing the rotor/flywheel (I) to 8. Remove the starter idler gears (F & G) from the the crankshaft;...
Page 65 CC952 CC966 10. Remove the shift fork and pin (D). 13. Remove the circlip, washer, and drive gear #1 (B) from the driveshaft; then account for the bushing and the spacer. CC953 11. Remove drive gear #2 (B). Account for washers on CC955 both sides of the gear.
Page 66 CC961 CD552 16. Remove the secondary stopper camshaft assembly. Account for the two shims. CC958 14. Remove driven gear (A) from the output shaft. CC962 NOTE: Note the alignment dots on the cam plate and camshaft for installing purposes. CC959 15.
Page 67: Right-Side Components
Removing Right-Side Components A. Oil Filter 1. Using Oil Filter Wrench (p/n 0644-389), remove the oil filter. CC964 CC967 2. If the engine has not been removed, lay the ATV on its left side; then remove the cap screws CC965 securing the right-side cover to the crankcase.
Page 68 5. Remove the starter clutch-shoe nut (left-hand threads) and washer from the driveshaft; then using a primary clutch shoe remover, remove the clutch shoe. ! CAUTION Care must be taken when removing the nut; it has “left-hand” threads. 6. Remove the primary drive one-way clutch from the starter clutch housing.
Page 69 CC077D CC970 9. Simultaneously, remove the primary clutch 10. Remove the nut and washer securing the oil pump assembly and starter clutch housing from their drive gear to the crank balancer shaft; then remove respective shafts. Account for the shims and the gear and account for the pin, gear, washer, and washers.
Page 70 14. Remove the circlip securing the oil pump driven gear; then remove the gear. Account for the pin and the washer. NOTE: Always use a new circlip when installing the oil pump driven gear. CC973 12. Release the tension from the gear shift cam stopper arm spring.
Page 71: Center Crankcase Components
Separating Crankcase Halves 1. Remove the five right-side 6 mm cap screws (one from inside the case) securing the crankcase halves; then remove the seven left-side 6 mm cap screws. Note the location of the different-lengthed cap screws and a wiring form. CC091D 17.
Page 72: Disassembling Crankcase Half
CC982 CC983 4. Using an appropriate crankcase separator and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins, a C-ring, and two washers. NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves.
Page 73 1. Remove the output shaft assembly (J). NOTE: For efficiency, if the driveshaft and/or countershaft are not being serviced, it is prefera- 2. Remove the two shift shafts (E and H). ble to leave them assembled. The technician should use discretion and sound judgment. 3.
Page 74: Servicing Components
Table of Contents (Servicing Components) NOTE: Critical engine/transmission specifica- tions are located at the beginning of this section. Servicing Top-Side Components ......3-30 Valve Assembly ..........3-30 Piston Assembly ..........3-35 Cylinder/Cylinder Head Assembly...... 3-37 CC115D Servicing Left-Side Components ......3-40 Recoil Starter ............
Page 75 2. Place the valve cover on the Surface Plate (p/n 2. Remove the valve seal and the lower remaining 0644-016) covered with #400 grit wet-or-dry spring seat. Discard the valve seal. sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the seal- ing surface for any indication of high spots.
Page 76 Measuring Valve Stem Measuring Valve Guide/Valve Stem Outside Diameter Deflection (Wobble Method) 1. Using a micrometer, measure the valve stem 1. Mount a dial indicator and base on the surface outside diameter. plate; then place the cylinder head on the surface plate.
Page 77 CC137D CC138D 2. Using the Standard Valve Guide Reamer (p/n Valve Seat/Guide Servicing Flow 0444-017), remove any burrs or tight areas from Chart the valve guide journals. CC142D 3. To install a valve guide, use a valve guide installer and gently drive a valve guide with a retaining clip into the bore from the valve spring side until the retaining clip just contacts the cyl- inder head.
Page 78 Measuring Rocker Arm (Inside Diameter) 1. Using a dial calipers, measure the inside diame- ter of the rocker arm. 2. Acceptable inside diameter range must be within specifications. Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diame- CC139D ter of the rocker arm shaft.
Page 79 3. Inspect the piston for seizure marks or scuffing. ! CAUTION Repair with #400 grit wet-or-dry sandpaper and water or honing oil. Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in NOTE: If scuffing or seizure marks are too deep severe damage to the piston.
Page 80 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. CC995 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each CD325 end and in the center. If measurement is not 2.
Page 81: Cylinder/Cylinder Head Assembly
CC141D Cleaning/Inspecting Cylinder 3. Place the cylinder head on the surface plate cov- ered with #400 grit wet-or-dry sandpaper. Using 1. Wash the cylinder in parts-cleaning solvent. light pressure, move the cylinder head in a fig- ure eight motion. Inspect the sealing surface for 2.
Page 82 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indi- cation of high spots. A high spot can be noted by a bright metallic finish.
Page 83 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. Measuring Camshaft to Cylinder Head Clearance CC127D 1. Remove the adjuster screws and jam nuts. Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced.
Page 84: Servicing Left-Side Components
CC145D CF060A 6. If clearance is excessive, measure the journals of 2. If damaged, the camshaft must be replaced. the camshaft. Servicing Left-Side Components RECOIL STARTER Recoil Starter Assy Reel Spiral Spring Ratchet Assy Ratchet CC287D Ratchet Guide NOTE: If the journals are worn, replace the cam- Rope Assy shaft;...
Page 85 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case; then remove the ratchet guide from the friction plate. CC039D ! WARNING During the disassembly procedure, continuous B602D downward pressure must be exerted on the reel so 5.
Page 86 Assembling/Installing 1. If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a coun- terclockwise direction until the complete spring is installed. NOTE: The spiral spring must seat evenly in the recoil case.
Page 87: Measuring Shift Fork (Thickness)
B604D B601D 7. Install the shaft, spring, and the spring cover. 10. With the 50 cm (20 in.) of rope exposed, hook the rope in the notch of the reel. 11. Rotate the reel four turns counterclockwise; then release the rope from the notch and allow the rope to retract.
Page 88: Measuring Shift Fork Groove (Width)
3. Shift fork to groove side clearance must be within specifications. Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. CC296D PRIMARY CLUTCH ASSEMBLY 2. Shift fork thickness must be within specifica- (Inspecting/Measuring/ tions.
Page 89 CC245D ATV1014 Inspecting Centrifugal Clutch 3. Maximum driven plate warpage must not Housing exceed specifications. Measuring Clutch Drive Plate 1. Inspect the clutch housing for burns, marks, (Fiber) Thickness scuffs, cracks, scratches, or uneven wear. 1. Using a calipers, in turn measure the thickness 2.
Page 90 Assembling Primary Clutch Pressure Disc Driven Plate Drive Plate Sleeve Hub Primary Gear Assy Washer Washer CF044A NOTE: When installing the driven plates for ease of installation, make sure they are placed onto the hub with the rounded side of the plates directed down.
Page 91: Inspecting Oil Pump
INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. CC924 5. Place the primary gear assembly on a clean, flat surface;...
Page 92 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. 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim.
Page 93: Crankshaft Assembly
CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. CC289D 3. Acceptable gap range must be within specifica- tions.
Page 94: Driveshaft
Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. CD335 ATV-1017 2. Acceptable width range must be within specifi- cations. DRIVESHAFT Disassembling CD336 1. In order, remove the reverse dog, circlip, washer, reverse driven gear, and bushing from the driveshaft.
Page 95 4. Remove the 4th driven gear from the driveshaft. Note the four small dogs facing toward the 3rd driven gear for assembling purposes. CD341 3. Remove the 1st driven bushing; then remove the 1st driven washer (left side) from the shoulder of the splined shaft.
Page 96 CD349 CD354 7. Remove the 3rd driven bushing from the drive- 10. Remove the 5th driven gear from the driveshaft. shaft. Note the location of the oil feed hole in the bushing and the matching oil supply hole in the driveshaft for assembling purposes. CC210D 11.
Page 97 1. In order, install the 2nd driven bushing, gear, washer, and circlip onto the driveshaft. CD358 CD359 CD359 AT THIS POINT CD358 To service secondary gears, see Servicing Center Crankcase Components this sub-section. Assembling CD357 Driveshaft 3rd Driven Lock Washer - Left 1st Driven Gear Driveshaft Bearing...
Page 98 CD355 CD351 3. Install the 3rd driven lock washer (left side). ! CAUTION Lock it into the groove closest to the 5th driven gear (as noted in disassembling) by rotating it It is very important to assure the oil feed hole in the when it is in the groove.
Page 99 CD346 CD343 7. Install the 4th driven gear onto the driveshaft making sure the four small dogs are facing toward the 3rd driven gear as noted in disassem- bling; then secure with the circlip. CD342A CD345 CD341 9. Install the 1st driven washer (right side) on the shaft making sure it lines up with the groove in the shaft;...
Page 100: Countershaft
10. Slide the reverse driven bushing onto the shaft making sure the oil port in the bushing aligns with the oil port on the shaft. CD334 CD337 ! CAUTION Failure to align the oil ports will result in serious engine damage. 11.
Page 101 CD396 CD405 3. Remove the 5th drive washer and 5th drive cir- 6. Remove the other 4th drive washer from the clip from the countershaft. countershaft. CD397 CD408 Assembling CD400 4. Remove the 3rd drive gear from the counter- shaft. Countershaft Shaft Bearing 2nd Drive Gear...
Page 102 CD408 CD401 2. Install the 4th drive gear making sure the bush- ing is in position; then install the other 4th drive washer onto the countershaft. Secure with the circlip. CD400 4. Install the 5th drive washer and 5th drive gear onto the countershaft.
Page 103: Assembling Crankcase Half
CD395 MD1024 3. With the key in position, slide the driven gear NOTE: The countershaft is now completely onto the crank balancer making sure the timing assembled for installation. marks are aligned. Assembling Crankcase Half NOTE: For ease of assembly, install components on the left-side crankcase half.
Page 104 4. Place the bearing C-ring into position in the 7. Place each of the four shift forks into its respec- crankcase; then install the front shaft (4x4) and tive gear or dog as noted during disassembling; rear shaft assemblies. then install the gear shift cam. ! CAUTION The bearing pins must be positioned into the crank- case.
Page 105: Joining Crankcase Halves
CC988 CC982 4. From the left side, install the three case half 8 9. Install the two gear shift fork shafts; then verify mm cap screws (two inside the case); then that the two crankcase half alignment pins are in tighten only until snug.
Page 106: Installing Right-Side Components
NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. ! CAUTION After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to In- stalling Top-Side Components. Installing Right-Side Components CC978 4.
Page 107 CC974 CD447 7. Install the gear shift shaft. 9. Place the chain into the crankcase; then secure it from the top side with a wire for ease of install- ing. CC973 C. Primary Driven Gear CC079D D. Primary Clutch 10. Install the primary driven washers and shims E.
Page 108 14. Install the starter clutch shoe and washer; then secure with the starter clutch-shoe nut (left-hand threads). Tighten to specifications; then using a center punch, stake the nut. CC078D NOTE: After placing the primary clutch assembly onto the shaft, pull out on the pressure plate tower to ensure the pressure plate has engaged the clutch hub properly and make sure the plates CD440...
Page 109: Installing Left-Side Components
17. Secure the clutch release arm with the cap screw 19. Tighten the cap screws in a crisscross pattern to coated with blue Loctite #243. Tighten securely. specifications. 20. Using the oil filter wrench, install a new oil fil- ter. CC073D F.
Page 110 CC964 CC960 3. Install the secondary stopper camshaft w/one 5. Install the driven gear onto the output shaft. inner shim and one outer shim. CC959 CC962 6. Place the bushing and washer onto the drive- NOTE: Care must be taken that the alignment shaft making sure the oil hole of the bushing dots on the camshaft plate and the camshaft are aligns with the oil hole of the driveshaft.
Page 111 10. Install the drive idler gear with one spacer and one washer. CC955 8. Place the select sliding dog gear onto the drive- shaft; then place a washer, drive gear #2, and CC952 another washer onto the driveshaft. 11. Install starter idler gear #2 and shaft with the chamfered side directed toward the crankcase.
Page 112 CC990 CC945 13. Install the two alignment pins into the left 16. Place the gear shift stopper w/spring and washer crankcase half. into position above the hi/low shift shaft making sure the spring and stopper are correctly posi- NOTE: Make sure that three washers and two tioned.
Page 113: Installing Top-Side Components
Installing Top-Side Components A. Piston B. Cylinder CC943 Cylinder Stud Bolt 19. In a crisscross pattern, tighten the cap screws Stud Bolt (from step 15) to specifications. Bolt Bolt Bolt Cylinder Gasket 0737-039 NOTE: If the piston rings were removed, install them in this sequence.
Page 114 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crank- case.
Page 115 C. Cylinder Head 6. Place the head gasket into position on the cylin- D. Valve Cover der. Place the alignment pins into position; then place the head assembly into position on the cyl- inder making sure the cam chain is routed through the chain cavity.
Page 116 MD1192 732-307B 9. In a crisscross pattern, tighten the four cylinder 14. Place the C-ring into position in its groove in the head cap screws (from step 7) to specifications; cylinder head. then tighten the nuts (from step 8) to specifica- tions.
Page 117 16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole. MD1137 18. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be ATV-1027 installed; then install the cap screw (threads coated with red Loctite #271).
Page 118 22. Depress the spring-loaded lock and push the NOTE: At this point, the rocker arms and plunger into the tensioner. adjuster screws must not have pressure on them. 27. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug.
Page 119: Installing Engine/Transmission
4. Remove the block from beneath the engine; then Engine/Transmission align the rear drive flanges and secure with four cap screws. Tighten to specifications. 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;...
Page 120 CD809 CC937 6. Install the upper engine mounting brackets to 9. Connect the following electrical components: two wire leads for the oil temperature and oil pressure the frame with two cap screws; then install the sensors, indicator lights, CDI, and voltage through-bolt and flange nut.
Page 121 AR604D CF172A 11. Connect the battery ground (negative) cable to 16. Place the reverse/high/low shift linkage w/bush- the crankcase cover. ing and washer onto the engine shift shaft and secure with the E-clip. AR600D CC935 12. Install the coil and connect the two wires; then install the high tension lead on the spark plug.
Page 122 CD785 CD766A 21. Install the front and rear fender panels and the front and rear racks (see Section 8). 22. On VP models, install the gas tank (see Section 23. Install the storage compartment and steering post access panel; then secure with reinstallable rivets.
Page 123 2. Remove the negative cable from the battery; then remove the positive cable. Remove the bat- Table of Contents tery vent hose; then remove the battery. (400 - Automatic Transmission) ! CAUTION Battery acid is harmful if it contacts eyes, skin, or Removing Engine/Transmission ......3-79 clothing.
Page 124 10. Disconnect the crankcase vent hose from the air 15. Remove the E-clip securing the shift rod to the cleaner housing. Remove the clamp securing the engine shift arm; then allow the shift rod to hang air intake hose to the carburetor; then remove by the pivot axle bolt.
Page 125 18. Remove the four cap screws securing the rear output shaft to the transmission; then push the shaft to the rear as far as possible. CC939 23. Remove the two cap screws securing the front upper engine mount to the frame. CD085 NOTE: It is advisable to lock the brake when loosening the cap screws securing the rear drive-...
Page 126: Top-Side Components
CF194 compression stroke. 29. Slightly raise the front of the engine to disen- gage the front driveshaft from the front output NOTE: Arctic Cat recommends the use of new yoke. gaskets, lock nuts, and seals and lubricating all internal components...
Page 127 MD1354A MD1136 3. Loosen the cap screw on the end of the cam chain tensioner; then remove the two Allen-head screws securing the cam chain tensioner assem- bly. Remove the tensioner assembly and gasket. MD1137 6. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head;...
Page 128 MD1132 MD1163 8. Remove the cam chain tensioner by lifting it AT THIS POINT from the chain cavity; then remove the two lower nuts securing the cylinder head to the cyl- To service valves and cylinder head, see inder, one in front and one in rear. Servicing Top-Side Components sub-section.
Page 129 15. Using Piston-Pin Puller (p/n 0644-328), remove the piston pin. Account for the opposite-side cir- clip. Remove the piston. NOTE: It is advisable to remove the oppo- site-side circlip prior to using the puller. MD1226A 13. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crank- case.
Page 130: Left-Side Components
B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT To service piston, see Servicing Top-Side Components sub-section. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components.
Page 131 CC946 MD1365 ! CAUTION Care must be taken that the remover is fully threaded onto the rotor/flywheel or damage may occur. 7. Using Magneto Rotor Remover (p/n 0444-075), break the rotor/flywheel assembly loose from the crankshaft. Remove the remover, the crank- shaft protector, the rotor/flywheel, and the starter clutch gear.
Page 132 MD1370 8. Remove the starter idler gear (No. 1) and starter idler gear (No. 2). MD1224 13. Remove two starter motor cap screws. MD1305 9. Remove the gear shift shaft assembly and MD1078 washer from the left-side crankcase. Note the 14.
Page 133: Right-Side Components
Right-Side Components AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion MD1307 and sound judgment.
Page 134 6. Remove the nut holding the driven pulley assembly; then remove the driven pulley assem- bly. MD1034 MD1068 7. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 4.
Page 135 D. Gear Position Switch E. Centrifugal Clutch Assembly F. Oil Pump Drive Gear G. Oil Pump Driven Gear NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. MD1043 12. Remove the one-way sprag clutch noting the direction of the green dot or the stamp tag OUT- SIDE for installing purposes.
Page 136 17. Remove the snap ring holding the oil pump driven gear. MD1016 14. Remove the cam chain. MD1019 NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 18. Remove oil pump driven gear. Account for the pin.
Page 137: Center Crankcase Components
Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which MD1060 need to be addressed and to service only those 20.
Page 138: Disassembling Crankcase Half
NOTE: Note the location of the bearing align- ment pin on the secondary output shaft. 2. Remove the reverse idler gear, spacer, and sleeve. Account for the washers. CC869 NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves.
Page 139 MD1327 MD1024 5. Remove snap ring and gear from the output side 9. Using Crankcase Separator/Crankshaft Remover of the gear cluster. Remove the gear cluster and (p/n 0444-009), remove the crankshaft. the inner shift fork together. Account for snap ring, gear, and washer. MD1330 ! CAUTION MD1328...
Page 140: Servicing Components
2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry Table of Contents sandpaper. Using light pressure, move the valve (Servicing Components) cover in a figure eight motion. Inspect the seal- ing surface for any indication of high spots. A...
Page 141 CC994 ATV-1082 2. Remove the valve seal and the lower remaining 2. Maximum runout must not exceed specifica- spring seat. Discard the valve seal. tions. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. 2.
Page 142 3. If a valve guide is out of tolerance, it must be replaced. Replacing Valve Guide NOTE: If a valve guide is worn or damaged, it must be replaced. 1. If a valve guide needs replacing, insert a valve guide remover into the valve seat side of the valve guide.
Page 143 Grinding Valve Seats NOTE: If the valve seat is beyond servicing, the cylinder head must be replaced. 1. Insert an exhaust valve seat pilot shaft into an exhaust valve guide. Slide an exhaust valve seat grinding tool onto the pilot shaft; then using light pressure on a driver handle and a deep socket, grind the exhaust valve seat until within specifications.
Page 144 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. CC144D 2. Insert each valve into its original valve location.
Page 145 Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. CC995 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore CC400D 1. Measure the piston pin outside diameter at each 2. Remove each ring by working it toward the end and in the center.
Page 146 Repair damaged threads using a “heli-coil” insert. 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 fig- ure eight motion. Inspect the sealing surface for any indication of high spots.
Page 147 (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indi- CC127D cation of high spots.
Page 148 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 149 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 150 Servicing Left-Side Components RECOIL STARTER 1. Recoil Starter Assy 2. Reel 3. Spiral Spring B600D 4. Ratchet Assy 5. Ratchet ! CAUTION 6. Ratchet Guide 7. Nut During the disassembly procedure, make sure all 8. Rope Assy 9. Cap Screw spring tension is released before continuing.
Page 151 9. Remove the spiral spring from the case by lift- ing the spring end up and out. Hold the remain- der of the spring with thumbs and alternately release each thumb to allow the spring to gradu- ally release from the case. 10.
Page 152 3. Apply low-temperature grease to the spring and hub. 4. Thread the end of the rope through the guide hole of the case; then thread the rope through the handle and secure it with a double knot. Install the protective cover into the handle. 5.
Page 153 INSPECTING OIL PUMP Servicing Right-Side 1. Inspect the pump for damage. Components 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary.
Page 154 CD048 CD050 3. Install the pilot bushing with the machined end ! WARNING directed down; then fit the bushing into the pul- ley hub. The spring assembly is under pressure. Extreme care must be taken when relaxing the spring. Always wear safety glasses. Use proper tools only. 6.
Page 155 8. Release the preload slowly; then continue to relax the spring until the wing nut is flush with the end of the threads. 9. Firmly holding the spring and spring holder, remove the wing nut; then remove the spring. CD056 Inspecting 1.
Page 156 Assembling 4. Install the movable face sleeve aligning the hole in the spring seat with the spring anchor hole in 1. Place the fixed face of the driven pulley on the the movable face. pulley compressor base making sure the dowel pins are engaged in the appropriate holes in the pulley face.
Page 157 Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY GEARS NOTE: When checking and correcting secondary CD052 gear backlash and tooth contact, the universal 8. Compress the spring until the spring holder joint must be secured to the front shaft or false nears the threads on the fixed face hub;...
Page 158 NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Shim Correction Under 0.05 mm (0.002 in.) Decrease Shim Thickness At 0.05-0.33 mm No Correction Required (0.002-0.013 in.) Over 0.33 mm (0.013 in.) Increase Shim Thickness Checking Tooth Contact...
Page 159 CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. CC289D 3. Acceptable gap range must be within specifica- tions.
Page 160 Measuring Crankshaft Assembling (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. 1. Reverse Driven Gear Dog 7. Bushing 2. Reverse Driven Gear 8. High Driven Gear 3.
Page 161: Assembling Crankcase Half
CRANK BALANCER DRIVEN GEAR Assembling Crankcase Half 1. Balancer Shaft 2. Washer 3. Driven Gear #1 4. Driven Gear #2 NOTE: For ease of assembly, install components 5. Spring on the right-side crankcase half. 6. Key 7. Pin NOTE: If the output shaft was removed, make 8.
Page 162 3. Apply a liberal amount of oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place. MD1329 7. Align the inner shift fork with the gear cluster and with the inner washer in place, install the gear cluster and inner shift fork.
Page 163: Joining Crankcase Halves
11. Install the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the pinion gear. NOTE: Align the bearing alignment pin on the secondary output shaft. MD1327 9. Install the input driveshaft. MD1316 Joining Crankcase Halves...
Page 164: Installing Right-Side Components
Installing Right-Side Components A. Oil Strainer/Oil Pump 1. Place the oil strainer and new O-ring into posi- tion beneath the crankcase. Tighten the Phil- lips-head screws (coated with red Loctite #271) securely. MD1008 ! CAUTION 4. From the left side, install the remaining crank- case cap screws;...
Page 165 MD1060 MD1017 4. Place the pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. NOTE: Always use a new snap ring when install- ing the oil pump driven gear.
Page 166 MD1043 10. Install gear position indicator switch making MD1117 sure the O-ring is well-oiled and properly posi- 13. Install the air intake plate. Apply red Loctite tioned. Tighten cap screws securely. #271 to the threads of the three Phillips-head cap screws; then install and tighten securely. MD1040 MD1342 B.
Page 167 18. Making sure the eight movable drive face rollers are in position, pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft. Coat the threads of the nut with red Loctite #271 and secure the movable drive face.
Page 168: Installing Left-Side Components
Installing Left-Side Components A. Starter Idler Gears B. Rotor/Flywheel 1. Place the crankshaft bearing retainer into posi- tion. Apply red Loctite #271 to the three Phil- lips-head screws. Install and tighten the three Phillips-head screws securely. MD1086 5. Install the cam stopper assembly. 6.
Page 169: Installing Top-Side Components
9. Install two alignment pins and place the left-side cover gasket into position. Install the left-side Installing Top-Side cover. Noting the different-lengthed 6 mm cap Components screws, the position of the shifter bracket, and the location of the long cap screw with the washer, tighten cap screws only until snug.
Page 170 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crank- case.
Page 171 5. While keeping tension on the cam chain, place 7. Install the four cylinder head cap screws with the front cam chain guide into the cylinder. washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on ! CAUTION the left (spark plug) side.
Page 172 NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft is necessary for alignment, do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position.
Page 173 CC404D MD1248 22. Depress the spring-loaded lock and push the plunger into the tensioner. MD1137 18. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be MD1146 installed; then install the cap screw (threads coated with red Loctite #271).
Page 174 C. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. MD1245 25. Loosen the adjuster screw jam nuts; then loosen the adjuster screws on the rocker arms in the valve cover.
Page 175: Installing Engine/Transmission
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 far as possible. CD824 5. Secure the upper engine mounts to the frame 2.
Page 176 11. Connect the gear position indicator connector (A), stator connector (B), and the CDI connector (C) to the main wiring harness. CF138A 9. Install the cooling ducts with clamps and tighten the clamps securely. CD797A 12. Connect the temperature sensor leads to the main wiring harness.
Page 177 CD785 CD782 22. Connect the hose to the fuel pump; then connect the vacuum hose and secure with hose clamps. CD793 19. Secure the shift rod to the engine with a new E-clip. CD766A 23. Place the storage compartment into position; then install the reinstallable rivets.
Page 178 Table of Contents ! CAUTION (500 - Automatic Transmission/ Battery acid is harmful if it contacts eyes, skin, or 650 H1) clothing. Care must be taken whenever handling a battery. Removing Engine/Transmission ......3-134 3. Remove the radiator access cover, steering post Top-Side Components.........
Page 179 8. Remove vacuum hose fuel-pump-to-carburetor hose. CD786 11. Remove the clamp securing the cooling duct boot to the V-belt housing; then remove the CD766A cooling duct boot from the V-belt housing out- 9. Loosen the clamp securing the air intake duct to let.
Page 180 CD782 CD803 13. Secure the carburetor assembly up and away 17. Remove the two coolant hoses from the engine; from the engine. then route the hoses out of the way. 14. Remove the E-clip securing the shift rod to the 18.
Page 181 CD794 CD806 21. On the right-side, disconnect the gear position 24. Remove the cap screw and flange nut securing indicator connector (A), stator connector (B), the upper engine bracket to the engine; then and the CDI connector (C). remove the bracket. CD797A CD807 22.
Page 182 CD810 CD812A 27. Remove the two engine mounting through-bolts. Account for a washer and a spacer on the bolts. CD813 30. Remove the block from under the engine and lower the engine; then remove the boot clamp CD809 from the front output drive yoke. 28.
Page 183: Top-Side Components
CC001D NOTE: Keep the mounting hardware with the CD773 covers for assembly purposes or thread them back into the head to keep them separated. Top-Side Components 2. Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws.
Page 184 CD211A CC013D 3. Loosen the cap screw on the end of the ten- 6. Remove the cap screw securing the chain ten- sioner; then remove the two Allen-head cap sioner (account for a washer); then remove the screws securing the tensioner adjuster assembly tensioner.
Page 185 AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC017D CC022D C. Cylinder CC018D D. Piston NOTE: Steps 1-9 in the preceding sub-section must precede this procedure.
Page 186 CC024D CC032D 14. Using the Piston-Pin Puller (p/n 0644-328), remove the piston pin. Account for the oppo- site-side circlip. Remove the piston. NOTE: It is advisable to remove the oppo- site-side circlip prior to using the puller. CC025D CC033D NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder (p/n 0444-006).
Page 187: Left-Side Components
B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT To service piston, see Servicing Top-Side Components sub-section. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components.
Page 188 NOTE: Inspect the inside of the left-side cover for any shaft washers that may have come off with the cover. Make sure they are returned to their respective shafts and that the starter idler gear spacer is on the shaft or in the cover. CC620 6.
Page 189: Right-Side Components
NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage AT THIS POINT should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in To service the magneto assembly, see Section 5. the loss of an alignment pin into the crankcase.
Page 190: Removing Right-Side Components
4. Remove the nut securing the fixed driven assembly; then remove the assembly. Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. Remove the cap screws securing the V-belt cover noting the location of the differ- ent-lengthed cap screws for installing purposes;...
Page 191 CD973A CD974A NOTE: For steps 8-14, refer to illustration ! CAUTION CC829B. Care must be taken when removing the cover so the cover gasket is not damaged. NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER.
Page 192 CC596 CC603 11. Remove the nut (left-hand threads) securing the NOTE: Account for and inspect the clutch hous- clutch shoe assembly (C). Account for a washer. ing seal. NOTE: The washer is also directional. The flat side of the washer must face toward the clutch assembly when installing.
Page 193: Center Crankcase Components
CC613 CC664 3. Remove the left-side cap screws securing the crankcase halves. Note the location of the differ- ent-lengthed cap screws. Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure.
Page 194: Disassembling Crankcase Half
Disassembling Crankcase Half NOTE: For steps 1-7, refer to illustration CC821B. A. Secondary Driven Shaft Assembly B. Crank Balancer Assembly C. Crankshaft D. Countershaft Assembly E. Driveshaft F. Reverse Idler Gear Assembly G. Gear Shift Shaft H. Shift Shaft with 2 Forks CC821B NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN...
Page 195 CC672 CD826 5. Remove the countershaft assembly (D). Account 8. Remove the crank balancer. for a washer on each end of the countershaft. NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crank- shaft.
Page 196: Servicing Components
1. Wash the valve cover in parts-cleaning solvent. 2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the seal- ing surface for any indication of high spots.
Page 197 ! 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 cylin- der head and remove the valves.
Page 198 ATV-1004 CC131D 2. Acceptable width range must be within specifi- 3. Push the valve from side to side; then from top cations. to bottom. Measuring Valve Face Radial 4. Maximum “wobble” deflection must not exceed Runout specifications. Measuring Valve Guide 1.
Page 199 Valve Seat/Guide Servicing Flow Chart CC142D 3. To install a valve guide, use a valve guide installer and gently drive a valve guide with a retaining clip into the bore from the valve spring side until the retaining clip just contacts the cyl- inder head.
Page 200 NOTE: Repeat procedure on the remaining intake valve seat. CC144D 2. Insert each valve into its original valve location. 3. Install the valve springs with the painted end of CC140D the spring facing away from the cylinder head. Lapping Valves NOTE: If the painted end is not visible, install the NOTE: Do not grind the valves.
Page 201 1. Place each compression ring in the wear portion 3. Inspect the piston for seizure marks or scuffing. of the cylinder. Use the piston to position each Repair with #400 grit wet-or-dry sandpaper and ring squarely in the cylinder. water or honing oil.
Page 202 ATV-1069 ATV-1085B NOTE: Note the direction of the exhaust side of Measuring Piston Skirt/ the piston (5) for correct ring end gap orientation. Cylinder Clearance 2. On the 500, install the compression rings (1 and 1. Measure the cylinder front to back in six places. 2) so the letter on the top surface of each ring faces the dome of the piston.
Page 203 3. Place the cylinder head on the surface plate cov- 1. Wash the cylinder in parts-cleaning solvent. ered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a fig- 2. Inspect the cylinder for pitting, scoring, scuff- ure eight motion.
Page 204 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 205 ATV1013A CC003D 2. The lobe heights must not exceed minimum 5. Match the width of the plasti-gauge with the specifications. chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve Inspecting Camshaft Bearing cover clearance. Journal 1.
Page 206 CF061A CC039D ! WARNING During the disassembly procedure, continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury. 2. Rotate the reel counterclockwise until the notch of the reel is near the rope guide in the case. Guide the rope into the notch and slowly allow the reel to retract until all spiral spring tension is released.
Page 207 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case; then remove the ratchet guide from the friction plate. B605D ! WARNING Care must be taken when lifting the reel free of B602D the case.
Page 208 Assembling/Installing 1. If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a coun- terclockwise direction until the complete spring is installed. NOTE: The spiral spring must seat evenly in the recoil case.
Page 209 Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. INSPECTING CENTRIFUGAL CLUTCH SHOE B601D 1. Inspect the clutch shoes for uneven wear, chips, 10. With the 50 cm (20 in.) of rope exposed, hook cracks, or discoloration.
Page 210 INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. CD048 3. Install the pilot bushing with the machined end directed down;...
Page 211 8. Release the preload slowly; then continue to relax the spring until the wing nut is flush with the end of the threads. 9. Firmly holding the spring and spring holder, remove the wing nut; then remove the spring. CD050 ! WARNING The spring assembly is under pressure.
Page 212 NOTE: Make sure the spacer is on the base or damage to the fixed face will occur when the spring is compressed. CD056 Inspecting 1. Inspect the pulley faces for wear, galling, or CD048 grooving. 2. Apply multi-purpose grease to the O-rings and grease seals on the movable face;...
Page 213 CF097 CD052 5. Install the spring over the hub and movable face 8. Compress the spring until the spring holder sleeve; then insert the end of the spring through nears the threads on the fixed face hub; then the sleeve and into the spring anchor hole in the using the handle, wind the spring holder coun- movable face.
Page 214 Servicing Center Backlash Measurement Shim Correction Crankcase Components Under 0.05 mm (0.002 in.) Decrease Shim Thickness At 0.05-0.33 mm No Correction Required (0.002-0.013 in.) NOTE: Whenever a part is worn excessively, Over 0.33 mm (0.013 in.) Increase Shim cracked, damaged in any way, or out of tolerance, Thickness replacement is necessary.
Page 215 ATV-0104 CC290D Correcting Tooth Contact 2. Maximum diameter must exceed specifications. NOTE: If tooth contact pattern is comparable to Measuring Connecting Rod the correct pattern illustration, no correction is (Small End Deflection) necessary. 1. Place the crankshaft on a set of V-blocks and 1.
Page 216 Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the con- necting rod at the big-end bearing. 2. Acceptable width range must be within specifi- cations. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. ATV-1017 2.
Page 217: Assembling Crankcase Half
Assembling 1. Washer - Drive Gear (R) 2. Drive Gear #2 3. Circlip 4. Reverse Gear Dog 5. Spacer 6. Washer 7. Bushing 8. Bearing 9. Reverse Driven Gear 10. Lock Washer 11. Countershaft 12. Lock Washer 13. Low Driven Gear 14.
Page 218 NOTE: It will be necessary to rotate the crank balancer until the counterweight is facing away from the crankshaft; then rotate the crankshaft clockwise into the journal area to allow the crank balancer to be fully seated. 5. Place the key into the crank balancer keyway; then install the crank balancer gear making sure the alignment dots on the crank balancer gear and the crankshaft gear align.
Page 219: Joining Crankcase Halves
9. Insert the two shift forks into the sliding dogs noting the direction of the tabs from disassem- bling; then install the shift fork shaft. NOTE: Make sure the shift fork tabs face upward and that they are properly seated into the shift cams.
Page 220 7. From the left side, install the eight case half 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 8. From the right side, install the 6 mm cap screws; then tighten only until snug.
Page 221: Installing Right-Side Components
CC711 CC661A 3. Install the oil pump onto the engine; then tighten AT THIS POINT the Phillips-head screws securely. After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to In- stalling Top-Side Components. Installing Right-Side Components 1.
Page 222 CC609 CF086 NOTE: When installed correctly, the sides of the 8. Install the clutch cover alignment pins into the drive and driven gears will be flush with each crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase. other.
Page 223 CD971 CC549 16. Place the V-belt into position on the driven pul- ley and over the front shaft. CD970 13. Place the driven pulley assembly into position and secure with the nut. Tighten to specifica- CC550 tions. NOTE: The arrows on the V-belt should point for- ward.
Page 224: Installing Left-Side Components
19. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to specifications. CC845 NOTE: The sharp side of the snap ring should be facing outward.
Page 225 6. Install the magneto cover and secure with the 11. Install the crossover tube on the water pump and cap screws. Tighten only until snug. cylinder head making sure the O-ring is properly positioned. 7. Place the starter cup into position on the crank- shaft making sure a new, lubricated O-ring is inside the cup.
Page 226: Installing Top-Side Components
NOTE: On the 500, the chrome (silver) ring should be installed in the top position. On the 650 Installing Top-Side H1, the ring with the orientation mark (MTOP) Components should be installed in the second (middle) groove and the ring with the orientation mark (M) should be installed in the first (top) groove.
Page 227 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. CC023D 5. Install the coolant hose onto the crankcase union and tighten the clamp.
Page 228 CC022D CC272D 7. Place the head gasket into position on the cylin- 9. Loosely install the five cylinder head nuts. der. Place the alignment pins into position; then place the head assembly into position on the cyl- 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) to 3.8 kg-m (27.5 inder.
Page 229 B. Camshaft lobes directed down (toward the piston). 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 align- ment hole (smallest) are aligned. ! CAUTION CD461 If any of the above factors are not as stated, go...
Page 230 18. Rotate the crankshaft until the second cap screw 21. Install the cylinder head plug in the cylinder securing the sprocket to the camshaft can be head with the open end facing downward and installed; then install the cap screw (threads toward the inside.
Page 231 CD469 CC528D 24. Using a flat-blade screwdriver, rotate the 26. Apply a thin coat of Three Bond Sealant (p/n adjuster screw inside the tensioner counter- 0636-070) to the mating surfaces of the cylinder clockwise until all tension is released; then head and valve cover.
Page 232: Installing Engine/Transmission
A. Turn the engine over until the piston reaches top dead center on the compression stroke. B. Place the valve adjuster onto the jam nut NOTE: Arctic Cat recommends that new gaskets securing the tappet adjuster screw; then rotate and O-rings be installed whenever servicing the the valve adjuster dial clockwise until the end ATV.
Page 233 CD824 CD803 5. Secure the upper engine mounts to the frame with the cap screws. Tighten only until snug. 6. Install two engine mounting through-bolts, two bushings, and two washers; then tighten the through-bolt flange nuts to specifications. Tighten the upper engine mount cap screws (from step 5) to specifications.
Page 234 CD810 CD787 11. Connect the gear position indicator connector (A), stator connector (B), and the CDI connector (C) to the main wiring harness. CD785 CD797A 12. Connect the temperature sensor wire to the main wiring harness. 13. Secure the wires to the frame with nylon ties. 14.
Page 235 20. Place the left-side footwell and foot peg in posi- tion on the frame; then secure with existing hardware. Tighten to specifications. CD766A 23. Place the side panels into position; then install the reinstallable rivets. CD782 24. Place the battery into position in the battery compartment;...
Page 236 Table of Contents ! CAUTION (500 - Manual Transmission) Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. Removing Engine Transmission......3-192 3. Remove the radiator access cover, steering post Top-Side Components.........
Page 237 8. Remove vacuum hose fuel-pump-to-carburetor hose. CD803 12. Remove the E-clip securing the shift rod to the engine shift arm; then allow the shift rod to CD766A swing forward and hang straight down from the 9. Remove the cap screws securing the left-side shift lever.
Page 238 CD787 AR600D CD786 AR604D 17. Remove the clamp securing the upper coolant 20. Remove the clamp securing the lower coolant hose to the thermostat housing; then disconnect hose to the water pump housing; then disconnect the hose. the hose. CC335D CC334D 18.
Page 239 22. Remove the engine/transmission mounting fas- teners in the following sequence: A. Upper: Two cap screws (bracket to frame) and one cap screw and nut (topside of the engine). CC126D 23. Raise the rear of the engine enough to allow the rear output flange to clear the output flange joint.
Page 240: Top-Side Components
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 25.
Page 241 2. Remove the 12 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 orienta- tion of the cylinder head plug. Note the location of two alignment pins.
Page 242 CC013D CC017D CC266D CC018D NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. 6. Remove the cap screw securing the chain ten- sioner (account for a washer); then remove the tensioner. CC016D 8.
Page 243 AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section. 9. Remove the cam chain guide. AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC024D CC022D CC025D C. Cylinder D. Piston NOTE: Steps 1-9 in the preceding sub-section must precede this procedure.
Page 244: Left-Side Components
B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. AT THIS POINT To service piston, see Servicing Top-Side Components sub-section. AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components.
Page 245 CC039D CC045D 2. Remove the flange nut securing the starter cup 4. Remove the inside circlip. to the crankshaft; then remove the starter cup. Account for the O-ring inside the cup. CC046D 5. Remove the two cap screws securing the speed CC041D sensor housing;...
Page 246 8. Using Side Case Puller (p/n 0644-262), remove the side cover. Account for a gasket, two align- ment pins, and an idle gear limiter bushing. NOTE: Inspect the inside of the left-side cover for the four shaft washers that may have come off with the cover.
Page 247 NOTE: To aid in installing, it is recommended 12. Remove the shift fork shaft (D) from the crank- that the assemblies are kept together and IN case boss; then remove the shift fork from the shaft. Remove the shift shaft assembly (E) from ORDER.
Page 248 CC059D CD159 16. Remove the two cap screws securing the starter to the crankcase; then remove the starter. Account for the wiring forms. CD154A 14. Remove the washer and driven gear (A) from the output shaft; then account for the bushing. CC065D 17.
Page 249: 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 CD549 To service any one specific component, only 18.
Page 250 CF066A CC034D 4. Remove the cap screw securing the impeller to NOTE: The water pump housing does not have the impeller shaft; then remove the impeller. to be removed when removing the right-side cover. Account for the rubber retainer and porcelain seal.
Page 251 CD168A CC074D 9. Remove the release plate. Account for four C. Primary Drive Clutch Shoe springs. D. Primary Driven Clutch E. Primary Drive Clutch Housing 10. Remove the primary drive clutch-shoe nut (left-hand threads) and washer from the drive- shaft; then using a primary clutch shoe remover, NOTE: Steps 1-6 in the preceding sub-section remove the clutch shoe.
Page 252 15. Remove the cam chain from the crankcase. 16. Remove the nut and washer securing the oil pump drive gear to the crank balancer shaft; then remove the gear and account for the pin and the spacer. CC076D 13. Scribe a line across the primary driven clutch assembly to aid in assembling.
Page 253 CC086D CC089D 19. Remove the cap screw securing the gear shift 21. Remove the three Phillips-head screws securing cam plate and guide to the gear shift cam; then the oil pump; then remove the oil pump. remove the cam plate and guide. NOTE: It may be necessary to use an impact driver to loosen the screws.
Page 254: Center Crankcase Components
CC163D CC530D 2. Remove the seven left-side 6 mm cap screws AT THIS POINT securing the crankcase halves. Note the location of the wiring form. Note the location of the dif- To service center crankcase components only, ferent-lengthed cap screws. proceed to Separating Crankcase Halves.
Page 255: Disassembling Crankcase Half
CC098D CF078A 5. Using the Crankcase Separator/Crankshaft Remover (p/n 0444-009) and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins, an O-ring, and a washer. NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves.
Page 256 A. Crank Balancer Assembly B. Crankshaft C. Balancer Drive Gear with Pin D. Countershaft Assembly E. Shift Shaft with Fork F. Gear Shift Cam G. Reverse Shift Cam H. Shift Shaft with 3 Forks I. Driveshaft Assembly J. Output Shaft K.
Page 257 CD826 CC115D 9. Remove the driven gear from the crank balancer AT THIS POINT assembly (A). Account for a key. To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. ! CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary.
Page 258 2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry Table of Contents sandpaper. Using light pressure, move the valve (Servicing Components) cover in a figure eight motion. Inspect the seal- ing surface for any indication of high spots. A...
Page 259 CC132D ATV-1082 2. Remove the valve seal and the lower remaining 2. Maximum runout must not exceed specifica- spring seat. Discard the valve seal. tions. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. 2.
Page 260 3. If a valve guide is out of tolerance, it must be replaced. Replacing Valve Guide NOTE: If a valve guide is worn or damaged, it must be replaced. 1. If a valve guide needs replacing, insert a valve guide remover into the valve seat side of the valve guide.
Page 261 Grinding Valve Seats NOTE: If the valve seat is beyond servicing, the cylinder head must be replaced. 1. Insert an exhaust valve seat pilot shaft into an exhaust valve guide. Slide an exhaust valve seat grinding tool onto the pilot shaft; then using light pressure on a driver handle and a deep socket, grind the exhaust valve seat until within specifications.
Page 262 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. CC144D 2. Insert each valve into its original valve location.
Page 263 Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. CC280D Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore CC400D 1. Measure the piston pin outside diameter at each 2. Remove each ring by working it toward the end and in the center.
Page 264 Repair damaged threads using a “heli-coil” insert. 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 fig- ure eight motion. Inspect the sealing surface for any indication of high spots.
Page 265 (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight CC127D motion. Inspect the sealing surface for any indi- 2.
Page 266 2. The lobe heights must not exceed minimum specifications. 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 267 5. Match the width of the plasti-gauge with the NOTE: With the weight extended, the unloader chart found on the plasti-gauge packaging to flat should be even with the camshaft journal. determine camshaft to cylinder head and valve cover clearance. CF061 NOTE: When the weight is released, the spring CC145D...
Page 268 ! WARNING Always wear safety glasses when servicing the recoil starter. Removing/Disassembling 1. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the starter. B601D 4. Slowly release the friction plate and lift the plate with ratchet guide free of the recoil case;...
Page 269 Cleaning and Inspecting NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all components. 2. Inspect the springs and ratchet for wear or dam- age. 3. Inspect the reel and case for cracks or damage. B604D 4.
Page 270 B605D B602D 6. Install the ratchet onto its spring making sure the 9. While pushing down on the reel, install the nut. end is properly installed on the reel. Tighten securely. B604D B601D 7. Install the shaft, spring, and the spring cover. 10.
Page 271 MEASURING SHIFT FORK (Thickness) NOTE: Whenever a shift fork is out of tolerance, replacement is necessary. 1. Using a calipers, in turn measure the thickness of the machined tip of each shift fork. CC292D 3. Shift fork to groove side clearance must be within specifications.
Page 272 2. In turn place each driven plate on the surface 2. Inspect the depth of the grooves in the clutch plate; then using a feeler gauge, measure shoes. If any shoe is worn to the bottom of the warpage in several locations. groove, replace the complete set.
Page 273 CC920 CF047A 2. Alternately install the drive plates and driven 4. Place the primary gear assembly w/clutch hub plates onto the hub (starting with and ending assembly in one hand, place the other hand on with a drive plate) making sure the tabs with the top of the clutch hub assembly, and flip the notches are all in line with each other.
Page 274 SECONDARY GEARS NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur. Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft.
Page 275 Correcting Tooth Contact 1. Remove the secondary driven output shaft assembly from the left-side crankcase half. NOTE: If tooth contact pattern is comparable to 2. Clean the secondary driven bevel gear teeth of the correct pattern illustration, no correction is old oil and grease residue.
Page 276 2. Zero the indicator and push the small end of the 3. Zero the indicator and rotate the crankshaft connecting rod away from the dial indicator. slowly. 3. Maximum deflection must not exceed specifica- ! CAUTION tions. Care should be taken to support the connecting Measuring Connecting Rod rod when rotating the crankshaft.
Page 277 CC227D CC223D CC226D CC222D 3. Remove the 1st driven bushing; then remove the 1st driven washer (left side) from the shoulder of the splined shaft. Remove the 4th driven cir- clip. CC225D CC221D CC224D NOTE: The teeth on the bushing must face the 1st driven gear.
Page 278 CC508D CC215D 4. Remove the 4th driven gear from the driveshaft. 6. Remove the 3rd driven gear from the driveshaft. Note the four small dogs facing toward the 3rd driven gear for assembling purposes. CC214D 7. Remove the 3rd driven bushing from the drive- CC219D shaft.
Page 279 CD247A CC209D 9. Remove the next 3rd driven lock washer (left side) by rotating it out of the groove. Note the groove closest to the 5th driven gear for assem- bling purposes. CC208D CC211D 10. Remove the 5th driven gear from the driveshaft. CC207D CC210D 11.
Page 280 Assembling 1. Driveshaft 2. 1st Driven Gear 3. 2nd Driven Gear 4. 3rd Driven Gear 5. 3rd Driven Bushing 6. 4th Driven Gear 7. 5th Driven Gear 8. Reverse Driven Gear 9. Reverse Dog 10. Reverse Driven Bushing 11. 3rd Driven Lock Washer - Right 12.
Page 281 CC210D CD248 3. Install the 3rd driven lock washer (left side). ! CAUTION Lock it into the groove closest to the 5th driven gear (as noted in disassembling) by rotating it It is very important to assure the oil feed hole in the when it is in the groove.
Page 282 CC216D CC220D 7. Install the 4th driven gear onto the driveshaft making sure the four small dogs are facing toward the 3rd driven gear as noted in disassem- bling; then secure with the circlip. CC221D CC219D CC222D 9. Install the 1st driven washer (right side) on the shaft making sure it lines up with the groove in the shaft;...
Page 283 10. Slide the reverse driven gear bushing onto the shaft making sure the oil port in the bushing aligns with the oil port on the shaft. CC226D CC842 ! CAUTION Failure to align the oil ports will result in serious engine damage.
Page 284 4. Remove the 3rd drive gear from the counter- shaft. 5. Remove the 4th drive circlip securing the 4th drive gear on the countershaft; then remove the first 4th drive washer and 4th drive gear. Account for the bushing. CD242 2.
Page 285: Assembling Crankcase Half
CC199D CD242 3. Install the 3rd drive gear; then install the 5th NOTE: The countershaft is now completely drive circlip onto the countershaft. assembled for installation. Assembling Crankcase Half NOTE: For ease of assembly, install components on the left-side crankcase half. NOTE: If the output shaft and gear were removed, make sure that the proper shim is installed.
Page 286 CC116D CD832A 2. Apply a liberal amount of engine oil to the 4. With the key in position, slide the driven gear crankshaft bearing. Using a propane torch, heat onto the crank balancer making sure the timing the bearing until the oil begins to smoke; then marks are aligned.
Page 287 CD232A CC107D 7. Install the reverse idle shaft with circlip making sure the oil hole in the shaft is facing downward; then install a washer, bushing, reverse idle gear, and a washer. CC106D 9. Engage the four forks to the gear shift cam; then install the reverse shift cam and spacer.
Page 288: Joining Crankcase Halves
CC104D CC098D 4. From the right side, install the three case half 8 NOTE: Prior to joining crankcase halves, turn the mm cap screws; then tighten only until snug. shift cam to ensure all gears shift properly. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.
Page 289: Installing Right-Side Components
CC095D CC163D 7. In a crisscross/case-to-case pattern, tighten the 8 2. Place the strainer cap into position on the mm cap screws (from steps 3-4) until the halves strainer making sure a new O-ring is properly are correctly joined; then tighten to specifica- installed and secure with the cap screws;...
Page 290 CC088D CC086D 5. Place the gear shift cam plate and guide onto the gear shift cam making sure the alignment pin was installed. Secure assembly with the cap screw coated with blue Loctite #243. Tighten securely. CF072A 7. Install the gear shift shaft. CF073A CC085D C.
Page 291 CF070A CD198B ! CAUTION The clutch sleeve hub and the pressure plate must be seated in the proper position. If any of the incor- rect positions are used, the hub and plate will have clearance between them and they will not operate properly.
Page 292 13. Place the primary drive one-way clutch into the starter clutch housing noting the word OUT- SIDE for proper placement. CD166A 17. Secure the clutch release arm with the cap screw coated with blue Loctite #243. Tighten securely. CD482 14. Install the clutch shoe and washer; then secure with the starter clutch shoe nut (left-hand threads).
Page 293: Installing Left-Side Components
CF067 CC027D 23. Using the oil filter wrench, install a new oil fil- NOTE: Care should be taken that the alignment ter. pins are installed in the right-side cover. 20. Place the gasket and right-side cover into posi- tion making sure the release roller guide remains correctly positioned and that the water pump drive adapter aligns;...
Page 294 2. Place the shift-indicator sending unit into posi- tion making sure the contacts and springs are inside the case and a well-oiled O-ring is prop- erly positioned. Secure with Phillips-head screws. CC063D 5. Install the spacer onto the driveshaft. CC049D CC258D 6.
Page 295 CC059D CC060D 8. Place the select sliding dog gear and washer 10. Place a washer on the driveshaft, the counter- onto the driveshaft; then place the #2 drive gear shaft, and the driven shaft. onto the driveshaft making sure the bushing and washer follow on the driveshaft.
Page 296 CC333D CD136 13. With the shift fork peg positioned in the shift 16. Place a washer on each end of the starter gear shaft assembly slot, install the shift fork in the assembly and install in the crankcase. select sliding dog gear. 17.
Page 297 CD134A CC041D 23. In a crisscross pattern, tighten the cap screws C. Cover (from step 21) to specifications. D. Speed Sensor Housing E. Hi/Low Shifter Assembly F. Recoil Starter NOTE: Steps 1-19 in the preceding sub-section must precede this procedure. 20.
Page 298: Installing Top-Side Components
CD069 CC039D 26. Install the inside circlip onto the hi/low range shift shaft with the sharp side of the circlip fac- ing the engine; then place the shift lever assem- Installing Top-Side bly part way onto the shaft. Components NOTE: Position the shift lever part way onto the splines and verify the subtransmission is in hi range.
Page 299 B. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. CC025D 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston.
Page 300 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover 24. Cylinder Head Plug 1. Cylinder Head Assy 25. Intake Pipe Assy 2. Valve Guide 26. O-Ring 3. Dowel Pin 27. Cap Screw 4.
Page 301 CC272D 732-307B 9. Loosely install the five cylinder head nuts. NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder. 13. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assem- bly through the chain and towards its seating position;...
Page 302 14. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylin- der ensuring the following. CF013A 16. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft.
Page 303 CC012D CD501 20. Install the cylinder head plug in the cylinder NOTE: The adjuster shaft will be drawn into the head with the opening of the plug directed tensioner as the adjuster screw is rotated clock- downward and toward the inside. wise.
Page 304 CD470 CC003D 29. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 28) securely. 30. Adjust valve/tappet clearance using the follow- ing procedure. NOTE: Use Valve Clearance Adjuster (p/n 0444-078) for this procedure. A.
Page 305: Installing Engine/Transmission
Tighten to specifications. CC001D 32. If removed, install the spark plug and tighten to specifications. Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets CD824 and O-rings be installed whenever servicing the 5. Install lower rear engine mounting ATV.
Page 306 CD806 AR604D 10. Connect the battery ground (negative) cable to the crankcase cover. CD807 7. Connect the crankcase breather vent hose and secure with the clamp. AR600D 8. Connect the lower coolant hose to the water 11. Install the coil and secure with two cap screws; pump housing and secure with the clamp.
Page 307 CC121D CD790 13. Install the air filter housing; then connect the crankcase breather and the inlet air duct. Secure with the clamps. CD786 15. Connect the speed sensor connector to the sen- sor housing. CD785 CD794 16. Install the exhaust pipe and secure with two cap CD787 14.
Page 308 CF138A CD766A 20. Connect the temperature sensor wire to the main harness. CD803 17. Swing the shift rod back into position on the engine shift arm; then secure with the E-clip. CD788 18. Place the left-side footwell and foot peg into 21.
Page 309 Installing Left-Side Components ......3-313 Installing Top-Side Components......3-315 Installing Engine/Transmission ......3-318 ATV-0108 26. Pour 2.9 L (3 U.S. qt) of premixed Arctic Cat Antifreeze (p/n 0638-395) into the cooling sys- Removing Engine/ tem. Allow coolant to settle and then fill to the Transmission bottom of the stand pipe in the radiator neck.
Page 310 Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury. 1. Remove the seat. 2. Remove the negative cable from the battery; then remove the positive cable.
Page 311 15. Remove the throttle cover from the front carburetor; then disconnect the throttle cable. KX075A 12. Remove the front and rear spark plug caps; then remove the oil pressure sending unit lead (I). KX136 16. Lift the carburetors above the frame and tie to the handlebar;...
Page 312 18. Loosen the muffler clamp; then remove two mounting bolts securing the muffler to the frame. Remove the muffler assembly accounting for one ring gasket and one exhaust pipe bush- ing seal. KX117A 21. Remove the rear engine mount through-bolt; then remove the rear engine mount brackets from the frame.
Page 313 24. Remove the engine/transmission assembly from the left side of the frame. NOTE: Tape over or cap all open hoses, lines, and vents to prevent contamination. Make sure that the gas tank valve is in the OFF position and the tank cap is securely tightened. Left-Side Components KX235 NOTE: For efficiency, it is preferable to remove...
Page 314 KX237 KX239 6. Place an oil pan under the left side of the engine; 8. Remove the ball bearing; then thread the fly- then install two 6 mm cap screws (B) into the wheel puller (A) into the rotor/flywheel. collar (A) and remove the collar. KX240 KX238 9.
Page 315 11. Remove the oil pump drive chain tensioner bolt (A); then remove the chain guide bolts (B) and Right-Side Components collar and the chain guides (C). Account for a pin, spring, and O-ring with the chain tensioner bolt. 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 316 KX244 KX245 3. Disconnect the belt failure detection connector and the engine brake actuator lead; then remove the cap screws securing the V-belt cover to the crankcase. KX232A 7. Hold the driven pulley with an appropriate holder; then remove the driven pulley nut and the driven pulley.
Page 317 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 KX247 To service any one specific component, only limited disassembly of components may be necessary.
Page 318 3. Remove the cap screws (A); then remove the 5. If the left-side components have not been cam chain tensioner (B). Repeat for the second removed, rotate the crankshaft counterclockwise cylinder. to position the rear cylinder at TDC on the com- pression stroke;...
Page 319 KX250A KX452 9. Remove the front cylinder head assembly and 12. Install a 6 mm cap screw (A) in the tapped hole account for two alignment pins (A), cylinder of the front camshaft drive gear cover (B) and head gasket (B), oil pipe (C), and camshaft remove the cover.
Page 320 KX254 KX257A 15. Remove the front camshaft drive chain from the 17. Place a clean, lint-free cloth under the piston; intermediate sprocket (A) on the right side; then then remove the piston pin retainer rings (A). remove the shaft from the engine. ATV2067 KX253 18.
Page 321 KX456 KX259 3. Wrap tape on the sprockets (A) to protect the crankshaft bushing in the case; then using pry Center Crankcase points (B), separate the crankcase and lift off the left side. Components NOTE: This procedure cannot be done with the engine/transmission frame.
Page 322 KX261 KX264 5. Remove the spacer (B) and reverse drive gear ! CAUTION (C) accounting for a needle bearing and spacer; Connecting rods are machined with the big end then remove the reverse idler shaft (A), shifter caps installed. Severe engine damage will result if (D), and shift rod (E).
Page 323 KX267 ATV2069 8. Remove the two needle bearings (A); then using 10. Measure the thickness of the shift fork at (A); a press, remove the driven shaft (B). then measure the shifter groove width (B). If they are out of specification, they must be replaced.
Page 324 KX272 KX275A 3. Remove the cap screws (A) securing the output NOTE: Check the bevel gears (A) for scoring, drive bevel gear housing; then remove the hous- chipping, or abnormal gear patterns; then check ing (B). the bearings by rotating the drive and driven gears.
Page 325 2. Place the rocker case on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry Table of Contents sandpaper. Using light pressure, move the (Servicing Components) rocker case in a figure eight motion. Inspect the sealing surface for any indication of high spots.
Page 326 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ATV-1004 2. Acceptable width range must be within specifi- cations. CC136D Measuring Valve Face Radial NOTE: The valve seals must be replaced. Runout 3. Remove the valve springs; then invert the cylin- der head and remove the valves.
Page 327 CC131D CC142D 3. Push the valve from side to side; then from top to 3. To install a valve guide, use a valve guide bottom. installer and gently drive a valve guide with a retaining clip into the bore from the valve spring 4.
Page 328 Valve Seat/Guide Servicing Flow NOTE: Repeat procedure on the remaining Chart intake valve. CC140D Lapping Valves NOTE: Do not grind the valves. If a valve is dam- aged, it must be replaced. 1. Remove all carbon from the valves. 2. Lubricate each valve stem with light oil; then ATV-0107 apply a small amount of valve lapping com- pound to the entire seating face of each valve.
Page 329 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil. NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston.
Page 330 Measuring Piston Skirt/ 2. Using a feeler gauge, measure each piston-ring Cylinder Clearance end gap. Acceptable ring end gap must be within specifications. 1. Measure the cylinder front to back in six places. CC280D CC397D Measuring Piston Pin (Outside 2. Measure the corresponding piston diameter at a Diameter) and Piston-Pin Bore point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore.
Page 331 CC141D Cleaning/Inspecting Cylinder 3. Place the cylinder head on the surface plate cov- ered with #400 grit wet-or-dry sandpaper. Using 1. Wash the cylinder in parts-cleaning solvent. light pressure, move the cylinder head in a fig- ure eight motion. Inspect the sealing surface for 2.
Page 332 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indi- cation of high spots. A high spot can be noted by a bright metallic finish.
Page 333 CC283D CC005D 2. Rotate the camshaft and note runout; maximum 2. Place a strip of plastigauge in each of the cam- tolerance must not exceed specifications. shaft lands in the cylinder head. Measuring Camshaft Lobe Height 3. Place the rocker case on the cylinder head and secure with the rocker case cap screws.
Page 334 CC145D KX279 6. If clearance is excessive, measure the journals of the camshaft. Servicing Left-Side NOTE: If the journals are worn, replace the cam- Components shaft; then measure the clearance again. If it is still our of tolerance, replace the cylinder head. Inspecting Automatic RECOIL STARTER Compression Release...
Page 335 Inspecting 1. Inspect the actuator lever assembly for worn or bent shaft, broken spring, or damaged roller. Replace if excessive wear or damage is detected. KX602A KX589A 2. Using a calipers, measure the width of the con- tact point of the plastic guide shoes. If the width is greater than 6 mm (0.24 in.), the actuator lever assembly must be replaced.
Page 336 KX601 CD904 2. Install the engine brake cover making sure the seal is not damaged; then install the engine brake actuator and secure with three cap screws. Tighten securely. CD897 B. Rest the rod ends on the plastic actuator lever tips;...
Page 337 KX573A KX588A 4. Relax the spring by removing the nut and spring DRIVEN PULLEY ASSEMBLY holder; then remove the spring seats (A), spring (B), and thrust plate (C). Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools.
Page 338 KX283 KX576A 7. Remove the spacers; then thoroughly clean all 4. Inspect the pins, bushings, and cam slots for wear, parts in a high flash-point solvent. flat spots, looseness, or cracking. Inspecting 1. Inspect the pulley faces for wear, galling, or grooving.
Page 339 KX580 KX284A KX581 KX573B 3. Place the assembled faces of the driven pulley 5. Loosen the nut and remove the spring holder; on the pulley compressor base. then remove the driven pulley assembly from the driven pulley compressor. DRIVE CLUTCH ASSEMBLY Disassembling 1.
Page 340 KX287 KX289A 4. Remove the shoes (B), nuts (C), ramp weight pins (D), and ramp weights (E) from the spider (A); then clean all parts thoroughly in a high flash-point solvent. KX290A 2. Inspect spider shoes (A) for wear or damage. If any are damaged, replace the complete set.
Page 341 4. Inspect the rollers (A) and washers (C) in the spider. If they are worn, replace the spider assembly (B). KX296 4. Install the spring spacer in the spider; then install the spring (A) in the spider groove. KX293 5. Install the alignment pins (C); then install the Assembling clutch cover aligning the arrows (B) on the clutch cover and spider.
Page 342 CC290D ATV2073 2. Maximum diameter must not exceed specifica- 5. Measure the connecting rod big end inside tions. diameter; then check the mark (A) to see if the measurement coincides with the mark. If there is NOTE: Always tighten connecting rod cap nuts no mark on the connecting rod, the big end to the specified torque value before making any inside diameter should be within specifications.
Page 343 2. Install and tighten four nut-holding bolts (A) in the four threaded holes. See illustration for loca- tion of assembly components. ATV2076 9. Measure the main bearing bore diameter (A) in the crankcase. It must be less than specifications. A. Nut-Holding Bolts E.
Page 344 DISASSEMBLING OUTPUT DRIVEN BEVEL GEAR ASSEMBLY AT THIS POINT If no abnormal chipping or bearing roughness is found, proceed to Installing Output Drive/Driven Bevel Gears in this sub-section. 1. Secure the driven bevel gear assembly hold- ing/compressing tool (C) in a vise; then set the housing assembly (A) on the holder, tighten holder nuts (D), and compress the damping KX300...
Page 345 KX306 KX309 5. Using a special deep socket (B), remove the out- put shaft retainer nut (A). Assembling Crankcase Half NOTE: Be sure to clean all parts thoroughly before assembly. Use compressed air to ensure that all oil passages are clear of blockage. ! CAUTION The crankcase halves are machined together;...
Page 346 6. Select connecting rod big end inserts using the following chart and the markings on the crank- shaft and connecting rod. Big End Bearing Insert Selection Con-Rod Big End Bore Crank Pin Bearing Insert Diameter Marking Diameter Mark Size Color None Brown None...
Page 347 NOTE: Do not move the connecting rod with plastigauge installed or the reading will be com- promised. 8. Remove the connecting rods and read the clear- ance with the gauge provided. The clearance must be 0.028-0.052 mm (0.0011-0.0020 in.) standard with a maximum service limit of 0.09 mm (0.0035 in.).
Page 348 KX317 KX320 15. Install reverse idler (C); then install the reverse 17. Make sure that the crankshaft, transmission drive gear (A) and spacer (B). shafts and shift shaft (A), oil tube (B), oil screen (C), O-ring (D), and alignment pins (E) are in place in the right crankcase half;...
Page 349 ATV2083 ATV2086 2. Apply blue Loctite #242 to the thread area (C), 4. Apply grease to the steel ball (A) and spring (B); except tip (D) of left case cap screw (3); then then install the steel ball, spring, washer (C), install and tighten the 8 mm cap screws to 2.0 and shift shaft positioning bolt (D).
Page 350 KX323 KX326 8. Press the drive bevel gear in until it bottoms; then 11. Place the output drive bearing housing (A) into the apply blue Loctite #242 to the threads (A) of the holding fixture (B); then apply blue Loctite #242 bevel gear retainer nut and with the raised side (B) to the threads of the bearing retainer (C).
Page 351 15. Secure the holding fixture (A) in a vise; then install the driven bevel gear (C), cam damper (D), spring (E), spring holder (B), and circlip (G). KX332 18. Install the drive bevel gear housing (B); then tighten the four cap screws (A) to specifications. KX329A 16.
Page 352 ATV2092 19. Set the dial indicator (A) against the output driveshaft spline groove; then rock the drive- shaft slightly until gear lash (play) is taken out in one direction (do not let driven shaft turn). 1. Ball Bearings 2. Drive Bevel Gear Shims Zero the dial indicator and rock the shaft in the 5.
Page 353 NOTE: The following illustration indicates that the drive gear is running too deep in the set. Increase drive housing shims and decrease driven housing shims. ATV2089 22. Increase or decrease shim thickness on the drive bevel gear housing until the correct contact pattern is obtained.
Page 354 KX336 KX339 26. Align the punch mark (B) on the intermediate 29. Install the position plate (A); then tighten cap shaft sprocket (A) with the index mark (C) on the screws (B) to specifications. crankcase. KX340 KX337 30. Install the front intermediate shaft chain guide (A); 27.
Page 355 KX342 KX345 32. To prepare the intermediate shaft chain tensioner ! CAUTION (A) for installation, release the stopper (B); then push the rod (C) into the housing and secure with a Make sure tension is kept on the front and rear cam chains whenever the crankshaft is rotated.
Page 356 2. Install the two bevel washers (A) with the concave side directed towards the driven pulley; then use the pulley holder (B) to hold the driven pulley and tighten the nut (C) to specifications. KX359 6. Adjust the installation length of the drive clutch using the following procedure.
Page 357 4. Install the upper chain guide (A) with the tab (B) directed downward; then install the lower chain Installing Left-Side guide (C) and collar (D). Tighten the chain guide Components attaching bolts to specifications. 1. Install a new circlip (A) securing the oil pump rotor (B) in rotor (C);...
Page 358 KX354 KX357 8. Install the one-way clutch so the flange (A) fits on 11. Apply grease to the alternator cover oil seal; then the recess (B) of the race; then install on the install the cover (B), cover cap screws (A), and rotor/flywheel and attach with the cap screws.
Page 359 ATV2097 ATV2098 ! CAUTION Installing Top-Side Incorrect installation of the piston rings will result in engine damage. Components 1. Install the pistons on the connecting rods making sure there is a circlip on each side and the open end of the circlip (A) does not align with the notch A.
Page 360 3. Apply clean engine oil to the piston skirts and cylinder walls; then install the cylinders and clamp (A) (rear only) and tighten the cylinder cap screws (B) to specifications. Install the cam chain guide (C) and the oil pipe (D). ATV2101 7.
Page 361 KX364 ATV2105 10. Apply clean engine oil to the camshaft; then 13. Using a wrench on the alternator bolt, turn the apply a thin coat of Three Bond Sealant (p/n crankshaft clockwise 270° and align the “TF” 0636-070) (A) to the outer surface of the cap mark (A) with the notch (B) in the inspection and the upper surface of the cylinder head.
Page 362 Engine/Transmission KX090 4. Align the engine with the front mount ears and install the front through-bolt; then install the rear NOTE: Arctic Cat recommends that new gaskets through-bolt. and O-rings be installed whenever servicing the ATV. 1. Using a suitable lifting device, set the engine/transmission into the frame cradle from the left side;...
Page 363 KX069A KX123 5. Tighten the rear bracket to frame bolts (from step 3) securely; then install the front and rear through-bolt nuts and tighten to specifications. 6. Install the front exhaust pipe with a new seal ring. Do not tighten the retainer nuts at this time. KX126 9.
Page 364 13. Connect the four disconnect plugs as shown; then connect the battery positive cable and starter lead to the starter relay. KX122 KX074 14. Connect the starter cable to the starter lug and tighten securely. 15. Connect the alternator and pick-up coil leads; then attach the reverse indicator lead and neutral indicator lead to the switches.
Page 365 KX119 KX118 19. Install the left footrest; then tighten the 10 mm cap screws to specifications and the 8 mm cap screws to specifications. 20. Install all fenders, side panels, and racks that were removed; then install the storage compart- ment cover.
Page 366 Choke Cable Free-Play (650 V-Twin) ....4-14 Engine RPM (Idle) ..........4-14 Gas Tank (400 VP) ..........4-15 Gas Tank (FIS Models).......... 4-16 Gas Tank Valve (400 VP) ........4-16 Gas/Vent Hoses ........... 4-17 Electric Fuel Pump (650 V-Twin) ......4-17 Vacuum Pulse Fuel Pump (400 FIS/500/650 H1) ........
Page 367: Carburetor Specifications
3-6 mm (1/8-1/4 in.) 3-6 mm (1/8-1/4 in.) 3-6 mm (1/8-1/4 in.) 3-6 mm (1/8-1/4 in.) Choke Cable Free-Play 3-6 mm (1/8-1/4 in.) Carburetor Schematics 400/500 (Keihin) 1. Cover 22. Spring 2. Screw 23. Plate 3. Spring 24. Screw 4. Vacuum Piston 25.
Page 368 650 H1 (Keihin) 1. Cover 25. Electric Choke 2. Screw 26. Choke Cover 3. Spring 27. U-Ring 4. Vacuum Piston 28. Diaphragm Assy 5. Spring Seat 29. Spring 6. Jet Needle 30. Cover 7. Needle Jet 31. Screw 8. Jet Holder 32.
Page 369: Carburetor (650 V-Twin)
8. Loosen the outer jam nut securing the throttle cable to the carburetor body; then route the Carburetor cable out of the way. (400/500/650 H1) ! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- ing, open flames, etc., in the area.
Page 370 3. Remove the three screws securing the primer housing. Account for the diaphragm assembly, spring, and U-ring (in the housing). CC752 6. Lift the float assembly from the carburetor. Account for the float needle valve. CC748 4. Remove the Phillips-head screws securing the float chamber;...
Page 371 CC758 CC761A 10. Unscrew and remove the idle speed adjuster 3. Install the slow jet. Tighten securely. assembly. Account for the spring and washer. 4. Install the main jet into the needle jet holder and ASSEMBLING tighten securely; then install the needle jet holder assembly into the carburetor and tighten 1.
Page 372 CC750 CC746 9. Place the top cover into position; then secure with the Phillips-head screws. Tighten securely. CC749 7. Place the U-ring into the primer housing. Posi- tion the spring and diaphragm assembly (lip CH015D toward the carburetor) onto the carburetor; then secure the assembly with the primer housing and INSTALLING three screws.
Page 373: Troubleshooting
Carburetor (650 V-Twin) ! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. TROUBLESHOOTING CC741 4. Connect the throttle cable to the actuator arm. 1.
Page 374 5. Remove the screws securing the lower air filter housing to the carburetors; then remove the lower housing and tape over the carburetor inlets. ! CAUTION Severe engine damage will occur if hardware items or other foreign objects are ingested by the engine on start-up.
Page 375 CC742 KX086B 8. Loosen the outer jam nut securing the throttle 11. Use tape to cover and seal the intake tubes. cable to the carburetor body; then route the cable out of the way. KX122 ! CAUTION KX137 9. Remove the Phillips-head screws holding the Any objects or liquid entering the intake tubes cable end plates (A);...
Page 376 1. Remove the vacuum chamber cover (A), spring (B), and vacuum piston (C); then remove the jet needle (D) and spring seat (E) from the vacuum piston. KX368 3. Bend the float valve contact tab (A) slightly to adjust float height. ATV2109 2.
Page 377 4. Remove the screws (A) and pump cover (B) 2. Install the main jet and slow jet. from the carburetor body; then remove the dia- 3. Insert the jet needle (A) into the vacuum piston phragm (C) and O-ring (D). (B);...
Page 378: Cleaning And Inspecting Carburetor
7. Place the float chamber into position making sure the O-ring is properly positioned; then Cleaning and Inspecting secure with Phillips-head screws. Carburetor NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. ! WARNING When drying components with compressed air, always wear safety glasses.
Page 379: Throttle Cable Free-Play
Adjust the idle to the correct RPM. Make sure the ATV-0047 engine is fully warm before adjusting the idle RPM. Engine Idle RPM Choke Cable Free-Play 400/500/650 H1 1250-1350 (650 V-Twin) 650 V-Twin 1050-1150 1. Locate the choke cable adjuster between the choke lever and the gauge pod;...
Page 380: Gas Tank (400 Vp)
Remove the covers. 3. Remove the air cleaner housing cover. KX029A Gas Tank (400 VP) 4. Disconnect the hose from the carburetor to the gas tank at the tank connection. 5. Cut the tie-down securing the gas hose to the cables and hoses.
Page 381: Gas Tank (Fis Models)
13. Lock Nut 20. Cap Screw Gas Tank Valve 7. Mounting Plate 14. Hose Clamp (400 VP) 0739-695 ! WARNING The ATV has a valve incorporated into the gas tank. Whenever any maintenance or inspection is made There are three positions: ON, RES, and OFF.
Page 382: Gas/Vent Hoses
Vacuum Pulse Fuel 3. Inspect the gasket and valve/tank mating sur- faces for damage or deterioration. Pump (400 FIS/500/650 H1) 4. Inspect for and remove any obstructions in the valve. The vacuum pulse fuel pump is a nonserviceable assembly. If the pump fails, it must be replaced.
Page 383: Oil Flow Charts
Oil Filter Relief Valve Drive and Driven Plates and Reverse Gears Bevel Gears Oil Pump Oil Strainer Oil Sump ATV-0111 400/500/650 H1 (Automatic Transmission) Intake and Exhaust Cam Drive Chain Cam Faces Intake, Rocker Arm Shaft Starter Clutch Camshaft Cylinder Wall...
Page 384: Oil Filter/Oil Pump
650 V-Twin 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Pressure Switch 5. Oil Filter 6. Oil Pipe 7. Crankshaft 8. Rear Cylinder Head 9. Rear Camshaft 10. Transmission Idle Shaft 11. Transmission Driveshaft 12. Front Cylinder Head 13.
Page 385 31. Circlip 16. Spring 0739-012 REMOVING/DISASSEMBLING CLEANING AND INSPECTING (400/500/650 H1) NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is 1. Remove the oil pump from the engine (see necessary. Right-Side Components in Section 3).
Page 386: Testing Oil Pump Pressure
Oil Temperature - 60°C (140°F) 2. Connect the Oil Pressure Gauge (p/n 0444-039) 500 (Manual Transmission) to the oil filter drain plug (400/500), in the oil pressure switch port (650 V-Twin), or to the OIL PRESSURE @ 3000 RPM upper oil cooler hose at the engine (650 H1).
Page 387: Oil Cooler (400)
INSTALLING Oil Cooler 1. Place the cooler into position in the frame. (400) 2. Secure the cooler to the frame with the cap screws and grommets. 1. Oil Cooler Assy 2. Oil Cooler 3. Screen 4. Thumb Screw 5. Shroud 6.
Page 388: Liquid Cooling System (500/650 H1/650 V-Twin)
Liquid Cooling System (500/650 H1/650 V-Twin) 1. Radiator Assy 2. Radiator 3. Radiator Screen 4. Radiator Cap 5. Grommet 6. Vent Hose 7. Thumb Screw 8. Fan Shroud 9. Fan 10. Machine Screw 11. Clamp 12. Clamp 13. Temperature Sender 14.
Page 389: Hoses/Thermostat (500/650 H1)
6. Disconnect the fan wiring from the main wiring harness; then remove the radiator/fan assembly and account for the grommets and collars. 7. Remove the fan/fan shroud assembly from the radiator. AF734D 4. Install the front bumper and front fender panel (see Section 8).
Page 390: Hoses/Thermostat (650 V-Twin)
D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear. NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. INSTALLING 1.
Page 391: Fan
3. Remove the impeller cap screw, washer, and gasket. 4. Remove the mechanical seal using this proce- dure. REMOVING A. Tap the tip of a small sheet metal screw into the inner-metal edge of the seal. 1. Remove the radiator (see Radiator in this sec- tion).
Page 392: Servicing Water Pump (500/650 H1 - Automatic Transmission)
Servicing Water Pump (500/650 H1 - Automatic Transmission) NOTE: When servicing the water pump, it will be necessary to install a new Oil Seal and a new Mechanical Seal. 1. Water Pump Assy 2. Cap Screw (Drain) 3. Gasket 4. O-Ring 5.
Page 393 3. Using Seal Removal Tool (p/n 0644-072), remove the mechanical seal and the oil seal from the bearing housing. CC784 6. Using an impact driver, loosen but do not remove the two Phillips-head cover screws. CC772 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
Page 394: Water Pump/Alternator Cover (650 V-Twin)
4. While holding the bearing housing assembly in position on the engine, slowly rotate the impel- ler until the impeller/shaft engages properly with its slot in the driven shaft. NOTE: The bearing housing will be flush with the engine when the two shafts are properly engaged. ! CAUTION Failure to properly engage the two shafts could cause serious engine damage.
Page 395 AT THIS POINT If the impeller is corroded or damaged, replace the impeller; then proceed to step 10. If additional service on the water pump/alternator cover is necessary, proceed to step 3. 3. Remove the alternator cover (see Removing Left-Side Components in Section 3); then using a suitable bearing driver, remove the water pump bearing from the alternator cover.
Page 396: Testing Electric Fuel Pump (650 V-Twin)
11. Install the recoil starter (see Installing Left-Side Components Section 3). 12. Install the coolant hoses onto the pump cover; then fill the cooling system with recommended coolant (see Section 2). Testing Electric Fuel Pump (650 V-Twin) ATV2117 AT THIS POINT Prior to removing the electric fuel pump, the following check...
Page 397 5. Connect a multimeter to the power supply leads with the red tester lead to the brown wire and the black tester lead to the black/red wire; then turn the ignition switch to the ON position. The meter should read battery voltage. If battery voltage is indicated and the fuel pump does not run, replace the pump assembly.
Page 398: Testing Vacuum Pulse Fuel Pump (400 Fis/500/650 H1)
Testing Vacuum Pulse Fuel Pump (400 FIS/500/650 H1) AT THIS POINT ATV2116 Prior to removing the vacuum pulse fuel pump, NOTE: If readings are erratic, clean the resistor the following check should be performed to wiper and resistor with clean alcohol and retest.
Page 399 REMOVING 1. Remove the seat; then remove the three clamps securing the gas hoses and vacuum hose and dis- connect the hoses. CD815 CD766A 2. Remove the two machine screws and flange nuts securing the fuel pump to the electrical tray; then remove the pump.
Page 400: Electrical System
Taillight - Brakelight ..........5-24 Brakelight Switch (Handlebar Control) ....5-4 Ignition Timing (400/500/650 H1) ......5-24 Oil Temperature and Cooling Fan Switches (400)... 5-5 Ignition Timing (650 V-Twin) ........5-25 Coolant Temperature and Cooling Fan Switches V-Belt Failure Mode Clearing (650 V-Twin).... 5-25 (500/650 H1/650 V-Twin) ........
Page 401: Specifications
Specifications 650 V-Twin IGNITION Ignition Timing 5° BTDC @ 1100 RPM 28° BTDC @ 5000 RPM Spark Plug Type NGK CR7E IGNITION Spark Plug Gap 0.7-0.8 mm Ignition Timing 10° BTDC @ 1500 RPM (0.028-0.032 in.) Spark Plug Type NGK CR7E Spark Plug Cap 4750-6250 ohms Spark Plug Gap...
Page 402: Rpm Limiter
Before installing the battery, make sure the ignition switch is in the OFF position. Receptacle/Connector (400/500/650 H1/650 V-Twin) 6. Place the battery into position in the ATV and secure; then connect the vent hose to the battery. NOTE: This test procedure is for either the 7.
Page 403: Brakelight Switch (Handlebar Control)
VOLTAGE 3. When the brake pedal is depressed, the meter (Wiring Harness Side) must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of 1. Set the meter selector to the DC Voltage posi- resistance, replace the switch. tion.
Page 404: Oil Temperature And Cooling Fan Switches (400)
Coolant Temperature Oil Temperature and and Cooling Fan Cooling Fan Switches Switches (400) (500/650 H1/650 V-Twin) NOTE: This model has an oil temperature switch and a cooling fan switch. 1. Connect the meter leads (selector in the OHMS position) to the switch contacts.
Page 405: Fan Motor
RESISTANCE 3. On the coolant temperature switch when the (Fan Motor Connector) water temperature reaches 112-118° (234-244° F), the meter should read a closed cir- cuit. ! CAUTION Always disconnect the battery when performing 4. On the coolant temperature switch, allow the resistance tests to avoid damaging the multimeter.
Page 406 4. Using the red tester lead, contact each end of the 0411-838 fuse holder connector terminals individually. 400 FIS/500/500 TBX (Automatic Transmission) 5. The meter must show battery voltage from one side of the connector terminal ends. NOTE: Battery voltage will be indicated from only one side of the fuse holder connector termi- nal;...
Page 407: Fuses
Fuses ! CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one spade end of CF202A the fuse; then connect the black tester lead to the other spade end.
Page 408: Indicator Lights (400 Vp)
4. The meter reading must be within specification. 2. On the 400/650 H1/650 V-Twin, connect the PEAK VOLTAGE (500/650 H1/650 black tester lead to either primary connector; on...
Page 409: Electronic Speedometer Speed Sensor
(400 FIS/500 manual models) or on the speed sen- 2. Connect the jumper ground wire to the neutral sor (500 auto/650 H1/650 V-Twin models) for con- terminal on the indicator light connector.
Page 410: Ignition Switch
5. Leave the black tester lead connected; then con- nect the red tester lead to the signal lead (S) pin. On the 400/500, the connector is the black three-wire one beneath the steering post cover. On 6. Slowly move the ATV forward or backward; the...
Page 411: Handlebar Control Switches
NOTE: If the meter shows no battery voltage, troubleshoot the battery or the main wiring har- Handlebar Control ness. Switches RESISTANCE ! CAUTION The connector is the yellow one next to the steering post. To access the connector, the steering post cover Always disconnect the battery when performing and the right-side fender splash shield must be resistance tests to avoid damaging the multimeter.
Page 412: Front Drive Selector Switch (400 Fis/500/650 H1/650 V-Twin)
5. Connect the red tester lead to the yellow/green wire; then connect the black tester lead to the Switch orange/white wire. (400 FIS/500/650 H1/650 V-Twin) 6. With the starter button depressed, the meter must show 0 DC volts. The connector is the two-wire black snap-lock one NOTE: If the meter does not show as specified, in front of the steering post.
Page 413: Front Drive Selector Actuator (400 Fis/500/ 650 H1/650 V-Twin)
Front Drive Selector Differential Lock Actuator Switch (400 FIS/500/650 H1/650 V-Twin) (400 FIS/500/650 H1/650 V-Twin) NOTE: With the engine stopped and the ignition NOTE: The following procedure does not include switch in the ON position, a momentary “whirring” the TRV models or the VP models.
Page 414: Magneto Coils (400/500/650 H1)
NOTE: If the meter shows other than specified in right side of the engine just above the brake cable any resistance test, replace the stator assembly. adjuster. PEAK VOLTAGE (400) NOTE: Test the connector that comes from the engine. NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter (p/n 1.
Page 415: Magneto Coils (650 V-Twin)
NOTE: The battery must be at full charge for 3. Crank the engine over using the electric starter. these tests. 4. The meter reading must be within specification. Magneto Coil (Trigger) 1. Set the meter selector to the DC Voltage posi- Magneto Coils tion.
Page 416: Starter Motor
3. With the engine running at a constant 3000 NOTE: The battery must be at full charge for RPM, all wire tests must be within specifica- these tests. tions. Magneto Coil (Trigger) ! CAUTION 1. Set the meter selector to the DC Voltage posi- Do not run the engine at high RPM for more than 10 tion.
Page 417 10. Remove the nut from the positive post. Account for the lock washer, flat washer, a fiber washer, and an O-ring. BC003 7. Remove the rear cover. 8. Slide the armature free of the starter housing. BC008 11. Remove the positive brush assembly from the starter housing.
Page 418 4. Inspect the brush leads for cracks, wear, or fray- C. Using the red tester lead, probe the commuta- ing. If any of these conditions exist, replace with tor end of the armature. The meter indicator new brushes and brush springs as a set. should not change.
Page 419 ASSEMBLING/INSTALLING 650 V-Twin 1. Starter Motor Assy 7. Washer Set 2. Brush Terminal Set 8. O-Ring 1. Starter Motor 9. O-Ring 17. Magnetic 3. Brush Holder Set 9. Through-Bolt Switch 2. Washer 10. Bolt 4. Spring 10. O-Ring 18. Holder 3.
Page 420 BC010 BC014 4. Install the armature into the starter housing; then 7. Apply a small amount of grease to the front while holding the brushes out, slide the commu- cover bearing and seal; then install the seal pro- tator into the brush holder. tector.
Page 421: Starter Relay
NOTE: If the meter showed battery voltage but the starter did not operate or operated slowly, inspect battery voltage (at the battery), starter motor condition, and/or ground connections. NOTE: If the meter showed no battery voltage, inspect the main fuse, ground connections, starter motor lead, battery voltage (at the battery), starter relay, or the neutral start relay.
Page 422: Cdi Unit (400 Fis/Tbx/500/650 H1/650 V-Twin)
Relays Neutral Start Relay check. (FIS Models) CDI Unit The relays are identical plug-in type located on the (400 FIS/TBX/500/650 H1/650 power distribution module. Relay function can be V-Twin) checked by switching relay positions. The relays are interchangeable. NOTE: The module and wiring harness are not a The CDI is located beneath the seat near the battery.
Page 423: Taillight - Brakelight
(negative) to the bottom terminal. 2. The taillight should illuminate. Ignition Timing (400/500/650 H1) 3. With the negative power supply still connected, connect the positive supply wire to the top ter- minal. The ignition timing cannot be adjusted; however, 4.
Page 424: Ignition Timing (650 V-Twin)
2. With the Arctic Cat Engine Tachometer (p/n 0644-275) connected, start the engine and run at the specified RPM. 3. Ignition timing should be according to specifica- tions. Model Timing 10° BTDC @ 1500 RPM 10° BTDC @ 1500 RPM 650 H1 10°...
Page 425: 100-Hour Belt Inspection Mode Clearing (650 V-Twin)
100-Hour Belt Inspection Mode Clearing (650 V-Twin) Every 100 hours, the word BELT will appear to alert for inspection. See Section 2 - Checking/Replacing V-Belt. To reset the belt indicator, use the following procedure. KX381 ! WARNING ! CAUTION V-belt inspection must be conducted in accordance Always disconnect the battery when performing with Section 2.
Page 426: Controller-To-Engine Brake Actuator Voltage (650 V-Twin)
1. Select DC Voltage on the multimeter (B); then 3. After two seconds, observe the meter until the turn the ignition switch ON. actuator stops. The controller output voltage should vary from 5-12 DC volts. If the voltage is 2. In the brake controller (A), connect the red tester not within specifications, check the for- lead to the orange wire terminal (9) and the ward/reverse detecting sensor.
Page 427: Output-To-Actuator Voltage (650 V-Twin)
Output-to-Actuator Speed Sensor Signal Voltage Voltage (650 V-Twin) (650 V-Twin) NOTE: This component is located on the right Select DC Voltage on the multimeter (B) and turn the ignition switch ON; then connect the red tester side of the engine and provides vehicle speed data lead to the black/green wire terminal (2) and the to the engine brake controller.
Page 428: Tilt Sensor Voltage (650 V-Twin)
Tilt Sensor Voltage (650 V-Twin) ! WARNING Incorrect installation of the tilt sensor could cause sudden loss of engine power which could result in loss of vehicle control resulting in injury or death. ! CAUTION CD706B Do not drop the tilt sensor as shock can damage OUTPUT VOLTAGE the internal mechanism.
Page 429 4. Tilt the sensor 60° or more to the left and right NOTE: When replacing the sensor after testing, observing the meter. The meter should read make sure the arrow marking is directed up. 4.0-8.0 DC volts after approximately one second in the tilted position.
Page 430 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 General Information..........6-2 Front Drive Actuator (400 FIS/500/650 H1/ 650 V-Twin) ............6-3 Front Differential (FIS Models) ........ 6-4 Drive Axles ............6-19 VP - Rear Suspension........... 6-24 Rear Gear Case (FIS Models).......
Page 431: Drive System
SPECIAL TOOLS Drive System A number of special tools must be available to the technician when servicing the gear case. NOTE: Some photographs and illustrations used Description in this section are used for clarity purposes only Boot Clamp Pliers 0444-120 and are not designed to depict actual conditions.
Page 432: Front Drive Actuator (400 Fis/500/650 H1/ 650 V-Twin)
Front Drive Actuator actuator to the rear enough to clear the slotted (400 FIS/500/650 H1/650 V-Twin) mounting tab and the selector shaft. NOTE: The actuator is not a serviceable compo- nent.
Page 433: Front Differential (Fis Models)
REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury. 2. Remove the drain plug and drain the gear lubri- cant into a drain pan;...
Page 434 AF894D AF628D 8. Remove the tie rod cotter pins and discard the 11. Pull the steering knuckle away from the axle pins. taking care not to damage the seals with the axle end. AF895D 9. Remove the tie rod lock nuts. KX151 12.
Page 435 AF610D CD517A 15. Using a slide hammer, remove the front axles. 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case; then remove the actuator. AF899D 16. Remove the inner fender panels. AG925 NOTE: On the 650 V-Twin, it will be necessary to 18.
Page 436 CD016 CD102 20. Free the differential assembly from the frame 2. Using a rubber mallet, remove the housing. mountings; then shift the differential assembly Account for a gasket. Remove the fork, collar, forward enough to disengage the front drive- and spring. Note the location of all the compo- shaft from the output yoke.
Page 437 CD114 AF983 4. Remove the input shaft from the pinion housing. AF984 CD107 5. Using a seal removal tool, remove the input shaft seal. Account for a spacer. KX219 Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing.
Page 438 AF993 KX222 4. On the 400 FIS/500/650 H1, install the input shaft into the housing; then install the front boot and secure with Boot Clamp (p/n 0423-393) and the rear boot with Boot Clamp (p/n 0423-411). AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing.
Page 439 CD103 CD110 6. On the 650 V-Twin, install the input shaft into the pinion housing; then secure in the bearing with a circlip. KX158 Disassembling Pinion Gear NOTE: This procedure can be performed on a KX210 rear gear case. 7. On the 650 V-Twin, place the pinion housing with new gasket onto the gear case housing;...
Page 440 KX173 KX176 3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring. KX177 KX174 NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. 4. Remove the splined coupler, shifter fork, pin, and spring of the differential lock assembly and set aside.
Page 441 KX181 CC878 7. Using the 48 mm Internal Hex Socket (p/n 9. Secure the pinion gear in a bearing puller; then 0444-104), remove the lock collar securing the remove the pinion bearing using a press. pinion gear assembly. Account for a collar, a bearing, and a shim. NOTE: On a front differential, the lock collar has right-hand threads.
Page 442 Shimming Procedure/Shim Selection 1. Press bearings into bores by outer ring to hard contact with seat. 2. Note the following shim selections (shims are nominally 1.5 mm/0.060 in. thick): A. Pinion Gear Sub-Assembly - add the value (A) on the gear case housing with 1.5 mm (0.060 in.);...
Page 443 CC883 CC891 2. Place the pinion assembly in a bearing puller; 5. Install the shift fork shaft w/spring into the gear then install the bearing using a press. housing making sure the shaft O-ring is posi- tioned to the inside. CC884 3.
Page 444 CD103 CC897 CD110 KX178 8. Install the proper shim onto the ring gear spider 9. Install the left bearing housing aligning the assembly making sure the chamfer side of the match mark to the mark on the differential hous- shim is facing toward the ring gear. Install the ing.
Page 445 KX175 CC885 2. Using a propane torch, heat the area surrounding the needle bearing to soften the Loctite. KX174 11. Making sure the O-ring is properly positioned on the gear case housing, install the housing CC886 with existing hardware. Account for the ID tag. Tighten the cap screws to specifications.
Page 446 CC888 CC891 2. Using a suitable driver, install the needle bear- 5. Install the pinion housing. ing into the gear case housing making sure the Removing/Installing Axle Seal bearing is seated. NOTE: Do not push the bearing too far into the NOTE: This procedure can be performed on a housing.
Page 447 CC901 CD859 2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid NOTE: Prior to installing the seal, apply grease lubricant into the differential and install the to the seal outside diameter. filler plug. Tighten to specifications. 4. Install the seal into the housing pressing evenly 3.
Page 448: Drive Axles
AF897D AF894D 8. Secure the tie rods with the lock nuts. Tighten to 10. Install the wheels and tighten to specifications. specifications; then install and spread the cotter 11. Remove the ATV from the support stand. pins. Drive Axles REMOVING REAR DRIVE AXLE (Fully Independent Suspension) 1.
Page 449 NOTE: Do not allow the brake calipers to hang from their cable/hose. ! CAUTION The calipers should be supported. If the calipers are allowed to hang from the cable/hose, damage may occur. 6. Slide the hub out of the knuckle and set aside. 7.
Page 450 7. Using a side-cutters (or suitable substitute), remove both outside boot clamps from the shaft. Note the position of the different-sized clamps for assembling purposes. CD023 4. Note the difference inside each bearing ring end for assembling purposes; then remove the bear- ing ring.
Page 451 CD754 ATV-1048 10. Using Boot Clamp Pliers (p/n 0444-120), secure 3. Apply 80 grams (2/3 of contents) of grease from both outside boot clamps. the pack into the bearing housing. 4. Install the bearing onto the shaft making sure the ! CAUTION recess of the bearing is facing the housing.
Page 452 NOTE: Pull the bearing ring out of the housing 4. If the brake calipers were removed, position until it contacts the circlip; then slide the ring in them on the knuckle and secure with existing cap screws. Tighten the auxiliary brake caliper half way.
Page 453: Vp - Rear Suspension
CD027 CC783 7. Install the wheel and tighten to specifications. ! CAUTION 8. Remove the ATV from the support stand and Care should be taken not to damage the brake release the brake lever lock. cable/hose when laying the calipers aside. Do not allow the calipers to hang from the brake 9.
Page 454 6. Maneuver the axle assembly rearward allowing the propeller shaft to disengage and the final drive boot to separate from the drive housing. DISASSEMBLING 1. Remove the cap screws securing the gear case panel; then remove the panel from the gear case. CC765 3.
Page 455 ASSEMBLING 1. Grease the splines of the ring gear. 2. Make sure the rear gear case/axle housing O-ring is properly positioned; then secure the axle housing to the rear gear case with two 33 mm (1.3 in.) cap screws. Tighten to specifica- tions.
Page 456 CC768 AF697D 5. Place the axle gasket on the axle housing. Rotate 3. Place the shock absorber into the frame mounts the axle shaft slightly to ensure proper engage- and secure using the cap screws and hex nuts ment with the gear case splines. tightened to specifications.
Page 457: Rear Gear Case (Fis Models)
CC762 AF960A 6. Install the wheels and tighten to specifications. AT THIS POINT 7. Remove the ATV from the support stand. For servicing the input shaft, pinion gear, needle bearing, and axle seal on FIS models, see Front NOTE: Check all fasteners for tightness and Differential (FIS Models) in this section.
Page 458 KX041 PR291 3. Remove the flange nut securing the hub. 3. Install the hub assembly onto the shaft. 4. Remove the brake caliper. CD009 4. Secure the hub assembly with the nut. Tighten PR243A only until snug. 5. Remove the hub assembly. 5.
Page 459: Hydraulic Brake Caliper
Hydraulic Brake Caliper NOTE: The brake caliper is a non-serviceable component; it must be replaced as an assembly (see Section 2). CD008 7. Install the wheel and tighten to specifications. CD006 8. Remove the ATV from the support stand. Back 6-30 Back to TOC Back to Section TOC...
Page 460 SECTION 7 - SUSPENSION TABLE OF CONTENTS Front and Rear Suspension Assembly Schematics ............7-2 Shock Absorbers ............. 7-3 Swing Arms (VP - Rear Suspension) ...... 7-4 Front A-Arms ............7-4 Rear A-Arms (FIS - Rear Suspension)....7-7 Wheels and Tires ............ 7-9 Back to TOC...
Page 461: Front And Rear Suspension Assembly Schematics
Front and Rear Suspension Assembly Schematics NOTE: Some components may vary from model to model. The technician should use discretion and sound judgment. FIS - FRONT VP - REAR 17. Knuckle Assy 1. Cap Screw 1. Retainer 18. Knuckle 2. Cap Screw 2.
Page 462: Shock Absorbers
Shock Absorbers REMOVING 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension. ! WARNING Make sure the ATV is solidly supported on the sup- AF730D port stand to avoid injury. CLEANING AND INSPECTING 2.
Page 463: Swing Arms (Vp - Rear Suspension)
2. On the right side, place the outer swing arm into position and secure to the axle housing with a Swing Arms cap screw and lock nut. Do not tighten at this (VP - Rear Suspension) time. 3. Secure the two right side swing arms to the REMOVING frame brackets with cap screws and hex nuts.
Page 464 CD007 AF626D 5. Remove the hub assembly. 10. Remove the cap screws securing the A-arms to the frame. 6. Remove the cotter pin and slotted nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle. AF610D 11.
Page 465 3. Inspect the A-arm for bends, cracks, and worn bushings. 4. Inspect the ball joint mounting holes for cracks or damage. 5. Inspect the frame mounts for signs of damage, wear, or weldment damage. INSTALLING 1. Apply green Loctite #609 to the entire outside diameter of the ball joint;...
Page 466: Rear A-Arms (Fis - Rear Suspension)
AF618D CD008 8. Apply grease to the hub and drive axle splines; 13. Install the wheel and tighten to specifications. then install the hub assembly onto the drive 14. Remove the ATV from the support stand. axle. Rear A-Arms (FIS - Rear Suspension) REMOVING 1.
Page 467 4. Apply grease on the drive axle splines; then install the hub assembly onto the drive axle. AF934 8. Slide the hub out of the knuckle and set aside. 9. Remove the cap screws and lock nuts securing CD009 the knuckle to the A-arms. Discard the lock 5.
Page 468: Wheels And Tires
TIRE SIZE ! 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 the General Speci- fications (see Section 1).
Page 469 NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Section 8).
Page 470 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-7 Steering Knuckles ........... 8-8 Measuring/Adjusting Toe-In........8-10 Front Rack ............. 8-11 Front Bumper Assembly ........8-12 Front/Rear Body Panel .......... 8-12 Front Body Panel/Side Panels (TBX/TRV/500/ 650 H1/650 V-Twin)..........
Page 471: Steering Post/Tie Rods
18. Ball Joint (Right) 19. Lock Nut 20. Cotter Pin 0739-774 REMOVING (400 VP) 4. Remove the cotter pin and slotted nut securing the side tie rod ends to the knuckles. Remove 1. Remove the gas tank (see Section 4).
Page 472 REMOVING (500/650 H1/650 7. Remove the retaining ring securing the ignition V-Twin) switch. 8. Remove the four cap screws securing the han- 1. Remove the ignition switch retaining ring; then dlebar caps (blocks) to the steering post; then remove the reinstallable rivets securing the move the handlebar out of the way.
Page 473 CD669 CD760 5. Remove the storage compartment box. 8. Using a suitable lift stand, raise the ATV enough to remove the front wheels; then remove the left-side and right-side splash panels. CD671 6. Remove the four cap screws securing the han- dlebar caps and speedometer bracket to the CD685 steering post;...
Page 474 7. Inspect the handlebar tube for cracks, wear, or unusual bends. 8. Inspect the handlebar grips for damage or wear. INSTALLING (400 VP) 1. Place the steering post into position; then place the upper steering post bearings and housings on the steering post and install the two cap screws through the housings and into the frame.
Page 475 AL600D AL600D 5. Insert the tie rod ends into the knuckles; then 2. Place the upper steering post bearings into the install the slotted nuts and tighten to specifica- housings; then position on the steering post and tions. Lock the nuts with new cotter pins. secure the housings to the frame with two cap screws.
Page 476: Handlebar Grip
5. Lower the ATV and place the handlebar and caps into position on the steering post; then position the speedometer on top of the caps and secure with the four cap screws. Tighten to spec- ifications. 6. Install the storage compartment box; then attach the storage compartment cover assembly by engaging the lugs into the slots and sliding rear- ward.
Page 477: Steering Knuckles
4. Install the plug on the head of the rivet. Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING AF726D 11. Remove the bearings. Make sure the ATV is solidly supported on the sup- port stand to avoid injury.
Page 478 5. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to specifications. CD009 9. Secure the hub assembly with the nut. Tighten only until snug. AF760D 6. Install the tie rod end and secure with the nut. Tighten to specifications;...
Page 479: Measuring/Adjusting Toe-In
AF785D 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 the seat catch brackets.
Page 480: Front Rack
AF786D AF789D 9. Measure the distance between the marks (at a NOTE: The distances from the inside rims to the height parallel to the belly panel) at the front frame tubes should be equal. If the measurements side; then record the measurement. are equal, proceed to step 8;...
Page 481: Front Bumper Assembly
3. Remove the front rack from the ATV. 2. Install the two flange bolts and lock nuts on the upper supports. Tighten all hardware securely. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, Front/Rear Body Panel cracked, or damaged in any way, replacement is necessary.
Page 482 4. Remove the left-side and right-side fender splash panels; then remove one press-in fastener and one reinstallable rivet from the left side and right side of the air-intake splash shroud. Do not remove the shroud. 5. Disconnect the four headlight connectors and the taillight/brakelight connector from the sock- ets.
Page 483 3. Making sure the body mounting grommets are in place, position the front and rear racks; then install the eight flanged cap screws and lock nuts. Do not tighten at this time. CF213A NOTE: To aid in removing the body without sepa- rating the front and rear panels, it is advisable to have an assistant help with lifting and guiding the body clear of the handlebar.
Page 484: Front Body Panel/Side Panels (Tbx/Trv/500/ 650 H1/650 V-Twin)
10. Connect the positive battery cable; then connect the negative battery cable. Tighten the battery terminal cap screws securely. 11. Install the battery cover/tool tray; then install the seat. Make sure the seat locks securely. Front Body Panel/ Side Panels (TBX/TRV/500/650 H1/650 V-Twin) CF201A 5.
Page 485 CD669 CD679A 3. Remove the storage compartment box; then remove the seat. CD680 6. Remove three reinstallable rivets securing the right side panel; then remove two torx-head cap CD671 screws securing the rear of the front panel to the 4. Remove the ignition switch lock collar and two frame.
Page 486 7. Remove the torx-head cap screws and nylon ties securing the left-side and right-side splash pan- els; then remove the panels. CD779 CD685 8. Remove one shoulder screw and four plastic riv- ets on each side to separate the front panel lower fenders from the left-side and right-side foot- wells.
Page 487 CD765A CD681 3. Make sure the four rubber grommets and bush- NOTE: It may be necessary to rotate the body ings are in place; then place the front rack into panel to the right to align the opening with the han- position and secure with four machine screws dlebar.
Page 488: Footrests
CD779 CD670A 7. Install the left-side and right-side splash panels 10. Install the steering post cover and secure with and tighten the cap screws securely. Install new the reinstallable rivets; then install and secure nylon ties in the appropriate locations. the radiator access panel.
Page 489: Belly Panel
NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. REMOVING MUFFLER (400/500/650 H1) 1. Clean the footrest in parts-cleaning solvent. 2. Inspect the footrest weldments for cracks or 1. Remove the two exhaust springs at the muf- unusual bends.
Page 490: Rear Body Panel/Rack (500/650 H1/650 V-Twin)
NOTE: For additional details on cleaning the muffler/spark arrester, see Section 2. INSTALLING MUFFLER (400/500/650 H1) 1. Place the muffler into position engaging the mounting lugs into the grommets; then slide the muffler forward.
Page 491 2. Place the rear rack in position with four bush- ings and secure with four machine screws and flanged nuts. Tighten securely. CD687A 4. Disconnect the battery (negative cable first); then remove the battery. CD690A 3. Install one shoulder screw and three plastic riv- ets (on each side) to secure the front of the rear body panel to the footwells.
Page 492: Side Storage Box (Tbx Models)
INSTALLING 6. Place the seat into position making sure it locks securely. 1. Place the side storage box into position on the frame; then secure with the two cap screws (A and B). Tighten cap screws to specifications. Side Storage Box (TBX Models) REMOVING 1.
Page 493: Adjusting Headlight
3. Remove the two cap screws and lock nuts secur- 2. While an assistant holds the cargo box in the ing the cargo box to the frame; then remove the raised position, place the lower end of the cargo cargo box and discard the lock nuts. box onto the lift support stud;...
Page 494: Taillight Assembly
NOTE: Some components may vary from model Taillight Assembly to model. The technician should use discretion and sound judgment. REMOVING/INSTALLING (400 TBX/500/650 H1/650 V-Twin) 1. Bulb 2. Taillight 1. To remove the seat, lift up on the latch release 3.
Page 495 CF226 CF229A 2. Lift the rear of the seat up; then pull slightly to 4. Lock the seat into position by pulling the two the rear and lift the seat off the mountings. latch handles to the rear and rotating them to the horizontal position.
Page 496 Auxiliary Brake Assembly Schematic ...... 9-4 Throttle Control ............9-4 Gearshift Pedal (Manual Transmission)....9-6 Drive Selector (FIS Models) ........9-6 Front Differential Lock (TBX/400 FIS/500/ 650 H1/650 V-Twin)..........9-6 Reverse Shift Lever ..........9-7 Speedometer/Tachometer/LCD (400 FIS/500/ 500 TBX/TRV/650 H1/650 V-Twin)....... 9-8...
Page 497: Hand Brake Lever/Master Cylinder Assembly
4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward Hand Brake Lever/ the pivot pin hole in the housing; then lay it Master Cylinder aside leaving the switch and wiring harness con- nected. Assembly NOTE: The master cylinder is a non-serviceable component;...
Page 498 INSTALLING 2. Install the brake hose on the master cylinder. Tighten to specifications. 1. Brake Assy 2. Screw 3. Cover 4. Screw 5. Clamp 6. Master Cylinder 7. Brake Lever Assy 8. Brake Lever Lock 9. Pin 10. Brake Switch 11.
Page 499: Auxiliary Brake Assembly Schematic
Auxiliary Brake Assembly Schematic 1. Brake Lever 19. Switch Bracket 2. O-Ring 20. Cap Screw 3. Washer 21. Spring 4. Cap Screw 22. Cap Screw 5. Spring 23. Caliper 6. Clevis Pin 24. Housing 7. Washer 25. Piston/Seal Set Assy 8.
Page 500 AF678D AL610D INSTALLING ADJUSTING 1. Place the return spring into the throttle control; 1. Slide the boot back to reveal the jam nut; then then place the bushing and actuator arm into loosen the jam nut. position. Secure with the cap screw, lock washer, and washer.
Page 501: Gearshift Pedal (Manual Transmission)
Front Differential Lock The gearshift pedal is attached to a ratchet mecha- nism in the transmission. Each time a gear is (TBX/400 FIS/500/650 H1/ selected, the gearshift pedal will return to its normal 650 V-Twin) position ready to select the next gear. To return to neutral, press down repeatedly (once for each gear) on the front of the pedal.
Page 502: Reverse Shift Lever
ATV forward and backward to align 1. Remove the E-clip securing the shift rod to the the differential lock splines and allow engagement. engine shift arm (TBX/TRV/400/500/650 H1). On the 650 V-Twin, remove two cap screws 3. Return the differential lock selector to the securing the front and rear shift rods together.
Page 503: Speedometer/Tachometer/Lcd (400 Fis/500/ 500 Tbx/Trv/650 H1/650 V-Twin)
1. Place the shift rod into position on the engine shift arm and secure with the existing E-clip Speedometer/ (TBX/TRV/400/500/650 H1). On the 650 Tachometer/LCD V-Twin, connect the front and rear shift arms with two cap screws. Only finger-tighten at this (400 FIS/500/500 TBX/TRV/ time.
Page 504 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications (400/500 - Manual Transmission) ............. 10-2 Torque Specifications (400/500 - Automatic Transmission/650 H1) ........10-3 Torque Specifications (650 V-Twin) ....... 10-5 Tightening Torque (General Bolts) ......10-6 Torque Conversions ..........10-7...
Page 505 Torque Specifications CHASSIS COMPONENTS (400/500 - Manual Transmission) Torque Part Bolted Part kg-m ft-lb Footrest Frame (8 mm) Footrest Frame (10 mm) DRIVE TRAIN COMPONENTS Shift Lever Shift Axle Torque Part Part Bolted To Shift Lever* Shift Axle kg-m ft-lb...
Page 506 Torque Specifications BRAKE COMPONENTS (400/500 - Automatic Torque Part Part Bolted To Transmission/650 H1) kg-m ft-lb Brake Disc* Brake Hose Caliper Brake Hose Master Cylinder DRIVE TRAIN COMPONENTS Brake Hose Auxiliary Brake Torque Part Part Bolted To Caliper kg-m ft-lb...
Page 507 ENGINE/TRANSMISSION ENGINE/TRANSMISSION (400/500 - Automatic Transmission) (650 H1) Torque Torque Part Part Bolted To Part Part Bolted To kg-m ft-lb kg-m ft-lb Clutch Shoe Crankshaft Clutch Shoe Crankshaft 31.8 Clutch Cover/ Hous- Crankcase Clutch Cover/ Hous- Crankcase ing Assy ing Assy...
Page 508 Torque Specifications SUSPENSION COMPONENTS (Front) (650 V-Twin) Torque Part Part Bolted To ft-lb A-Arm (All) Frame DRIVE TRAIN COMPONENTS Ball Joint Cap Screw Knuckle Torque Shock Absorber Frame Part Part Bolted To kg-m ft-lb Shock Absorber Upper A-Arm Engine Mounting Frame Knuckle A-Arm...
Page 509: Tightening Torque
Tightening Torque ENGINE/TRANSMISSION (cont) Torque (General Bolts) Part Part Bolted To ft-lb Water Pump Cover Alternator Cover Pick-Up Coil Alternator Cover Thread Tightening Torque Type of Bolt Diameter Stator Alternator Cover kg-m ft-lb A (mm) Alternator Cover Alternator Hous- (Conventional or 0.2-0.4 1.5-3.0 4 Marked Bolt)
Page 510 Torque Conversions ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 11.2 11.3 11.5 11.6 11.8 11.9 12.0 12.2 12.3 12.5 12.6 10.0 12.8 10.1 12.9 10.2 13.0 10.4 13.1 10.5 13.3 10.7 13.4 10.8 13.6 10.9 13.7 11.1 13.8 Back 10-7...
Page 511: Troubleshooting
SECTION 11 - TROUBLESHOOTING TABLE OF CONTENTS Engine ..............11-2 Drive ..............11-5 Fuel System ............11-6 Electrical..............11-7 Steering/Suspension ..........11-9 Brakes ..............11-10 11-1 Back to TOC...
Page 512: Engine
Engine NOTE: A Condition/Remedy marked with an asterisk (*) is for manual transmission models only. 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 - seated poorly 2.
Page 513 Problem: Engine noisy (Noise seems to come from clutch) Condition * Remedy * 1. Crankshaft splines - bearings worn 1. Replace crankshaft - bearings 2. Countershaft - hub splines worn 2. Replace countershaft - hub 3. Clutch plate teeth worn 3.
Page 514 Problem: Transmission will not shift back Condition * Remedy * 1. Reverse shift cam broken 1. Replace cam 2. Shift shafts rubbing - sticking 2. Replace shafts 3. Gearshift forks distorted - worn 3. Replace forks 4. Gearshift lever return spring broken - damaged 4.
Page 515: Drive
Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder 5.
Page 516: Fuel System
Fuel System Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket 4. Starter valve not operating properly 4.
Page 517: Electrical
Electrical Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.
Page 518 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Recharge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Repair - replace brushes 4. Starter relay defective 4. Replace relay 5.
Page 519: Steering/Suspension
Steering/Suspension 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 incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.
Page 520: Brakes
Problem: Rear wheel oscillation Condition Remedy 1. Rear wheel hub bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4. Wheel hub cap screws loose 4. Tighten cap screws 5.

This manual is also suitable for:

400 tbx 400 trv

Arctic Cat 400 Service Manual

Section 1 - General Information

Section 2 - Periodic Maintenance/Tune-Up

Section 3 - Engine/Transmission

Table of Contents

Servicing Components

Table of Contents

Table of Contents

Table of Contents

Section 4 - Fuel/Lubrication/Cooling

Section 5 - Electrical System

Section 6 - Drive System

Section 7 - Suspension

Section 8 - Steering/Frame

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Arctic Cat 400