Drive System; General Information - Arctic Cat 400 Service Manual

Drive System

NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.

General Information

All gear cases are tagged beneath a cover bolt. This
tag is marked with a production date code, sequence
code, and a ratio code.
A. A "6" on the lower-right corner indicates a
3.6:1 gear set ratio (10:36 teeth).
B. A "1" on the lower-right corner indicates a
3.1:1 gear set ratio (11:34 teeth).
The die-cast aluminum housings have been assem-
bled with thread-rolling screws (trilobular). When
assembling with these screws, start the screws care-
fully into the housing; then use the following torque
values.
Size New Housing
M6 1.1-1.3 kg-m
(Torx T-30 Recess) (8-9.5 ft-lb)
M8 3.5-4.3 kg-m
(Torx T-40 Recess) (25-31 ft-lb)
M10 5.1-6.3 kg-m
(Torx T-50 Recess) (37-45.5 ft-lb)
SPECIFICATIONS
Specific specifications regarding the gear cases
(capacities, lubricant type, etc.) can be found in Sec-
tion 1 of this manual.
Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.)
Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.)
6-2
Reassembled
Housing
0.9-1.2 kg-m
(6.5-9 ft-lb)
2.9-3.5 kg-m
(21-25 ft-lb)
4.3-5.3 kg-m
(31-38 ft-lb)
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SPECIAL TOOLS
A number of special tools must be available to the
technician when servicing the gear case.
Description
Boot Clamp Pliers
Pinion Gear/Shaft Removal Tool
Slide Hammer w/CV Joint Attachment
CV Joint Attachment (Only)
Internal Hex Socket (48 mm)
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
TROUBLESHOOTING
If a noise is heard from the gear case area, it can be
difficult to locate and/or diagnose. If the noise is
related to wheel speed, but not to engine RPM, the
problem is probably in the final drive or
engine/transmission bevel gear set. When a problem
is localized, a number of inspections must be made
to pinpoint that problem. The most obvious of the
inspections include CV boots, wheel and hub nut
tightness, wheel bearing damage, gear case lubricant
contamination, low lubricant level, seal leakage, CV
joints, or selector arm.
NOTE: Small metallic particles will collect on the
magnetic drain plug as a normal part of break-in
and will also give a metallic cast to drained lubri-
cant. Contamination would include large particles
or water which gives a "milky" look to the lubri-
cant.
NOTE: Lubricant on a new pinion housing
assembly could be grease. If the front of the gear
case is leaking at the rear drive boot, wipe excess
lubricant from the bottom of the pinion housing;
then operate the ATV for a period of time. Inspect
the pinion housing area for any signs of leakage. If
lubricant is again on the bottom of the pinion
housing, the seal must be replaced.
Additional troubleshooting could include the fol-
lowing.
• Binding/abrupt motion: CV boot torn (grease loss,
foreign object damage, broken cage); gear lubri-
cant loss or not filled (bearing seizure, broken gear
teeth, seal leakage, bladder or hose leakage,
missing filler/drain plug).
• Noise from drive system: wheel or gear case bear-
ing damage, improper gear backlash, improper
assembly, low or no gear case lubricant.
• Lockup: gear case lubricant loss or not filled, water
contamination causing bearing seizure.
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p/n
0444-120
0444-127
0444-123
0444-119
0444-104
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