Arctic Cat XC 450 2016 Service Manual
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Arctic Cat XC 450 2016 Service Manual

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Summary of Contents for Arctic Cat XC 450 2016

  • Page 1 SERVICE MANUAL www.arcticcat.com www.arcticcat.com...

  • Page 2: Table Of Contents

    2016 450 XC Service Manual Table Of Contents General Information/Foreword ........2 Fuel/Lubrication/Cooling..........70 Specifications..............2 Throttle Body ..............70 Torque Specifications ............3 Gas Tank ................71 Torque Conversions (ft-lb/N-m) .......... 4 Oil Filter/Oil Pump ............72 Gasoline - Oil - Lubricant ........... 4 Liquid Cooling System............73 Preparation For Storage.............

  • Page 3: General Information/Foreword

    When replacement of parts is necessary, use only genuine Ignition Timing 10° BTDC @ 1500 RPM Arctic Cat ATV parts. They are precision-made to ensure Spark Plug Cap 5000 ohms high quality and correct fit. Refer to the Illustrated Parts...

  • Page 4: Torque Specifications

    VALVES AND GUIDES SUSPENSION COMPONENTS (Front) Valve Face Diameter (intake) 35.0 mm Torque (exhaust) 30.5 mm Part Part Bolted To ft-lb Valve/Tappet (intake) 0.08-0.12 mm 0.15-0.20 mm Clearance (cold engine) (exhaust) A-Arm Frame (intake) 0.1 mm Knuckle Ball Joint Valve Guide/Stem 0.3 mm Clearance (max) (exhaust)

  • Page 5: Torque Conversions (Ft-Lb/N-M)

    35.4 69.4 103.4 36.7 70.7 104.7 CAUTION 38.1 72.1 106.1 Do not use white gas. Only Arctic Cat approved gaso- 39.4 73.4 107.4 line additives should be used. 40.8 74.8 108.8 RECOMMENDED ENGINE/ 42.2 76.2 110.2...

  • Page 6: Preparation For Storage

    1. Clean the ATV thoroughly. Arctic Cat recommends the following procedure to pre- pare the ATV for storage. An authorized Arctic Cat ATV 2. Clean the engine. Remove the cloth from the exhaust dealer should perform this service; however, the owner/ system.

  • Page 7: Periodic Maintenance

    Rinse in warm water; then press and squeeze. NOTE: Foam Air Filter Cleaner and Foam Air Fil-  ter Oil are available from Arctic Cat. 5. Dry the element. KC445A 6. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element.

  • Page 8: Valve/Tappet Clearance

    CAUTION A torn air filter element can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.

  • Page 9: Testing Engine Compression

    3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder VALVE/TAPPET CLEARANCE head well away from the spark plug hole. Intake 0.076-0.127 mm (0.003-0.005 in.) Exhaust 0.152-0.203 mm (0.006-0.008 in.) 4.

  • Page 10: Muffler/Spark Arrester

    ATV0052C AL611D A new spark plug should be tightened 1/2 turn once the 2. Turn the adjuster until the throttle cable has proper washer contacts the cylinder head. A used spark plug free-play of 3-6 mm (1/8-1/4 in.) at the lever. should be tightened 1/8 - 1/4 turn once the washer con- tacts the cylinder head.

  • Page 11: Front Differential/Rear Drive Lubricant

    4. Remove the drain plug from the bottom of the engine 13. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than and drain the oil into a drain pan. the illustrated “F”...

  • Page 12: Driveshaft/Coupling

    Shift Lever CHECKING ADJUSTMENT ATV0082A KC165 With the engine stopped and the brake lever lock engaged, turn the ignition switch to the ON position; then shift the transmission into each of the gear positions and note that the gear position indicated on the LCD corre- sponds to the gear position selected by the lever.

  • Page 13: Hydraulic Brake Systems

    Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake sys- tem, use the following procedure. 1. With the master cylinders in a level position, check the fluid level in the reservoirs. On the hand brakes if the level in the reservoir is adequate, the sight win- dows will appear dark.

  • Page 14: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury or death.
  • Page 15 3. Lower the brake pedal down to the foot wells and remove the reinstallable rivet from the CVT cut-out in the foot well. 4. Remove the cap screws from the CVT cover and remove the cover accounting for two alignment pins. 5.
  • Page 16 KC128 KC141 4. Remove the cap screw from the fixed driven face; then rotate the pulleys counterclockwise until the driven pulley faces are together. 5. With the two alignment pins installed in the V-belt housing and a new V-belt cover gasket in place, install the V-belt cover.

  • Page 17: Steering/Body/Controls

    3. Remove the shift lever knob. Steering/Body/Controls 4. Remove two reinstallable rivets, two fender bolts, and four cap screws; then lift the front fender panel off and set aside. Account for the shift lever spring. The following steering components should be inspected periodically to ensure safe and proper operation.

  • Page 18: Rear Body Panel

    CLEANING AND INSPECTING 3. Place the gas tank cover into position and secure with the existing hardware; then install the two cap 1. Clean all rear body panel components with warm screws securing the rear of the panel to the frame. soap and water.
  • Page 19 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deterioration. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 6. Inspect the bearing halves, bearing caps, and bearing housings for cracks or wear.

  • Page 20: Speedometer/Lcd Gauge

    Handlebar Grip REMOVING 1. Loosen but do not remove the cap screw in the end of the handlebar; then tap lightly on the head to dis- lodge the handlebar plug. KC184A 4. Place the handlebar and caps in place on the steering post and with the handlebar correctly positioned, tighten the cap screws to 20 ft-lb.

  • Page 21: Throttle Control

    2. Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up. NOTE: A quick, firm push is required to seat the  grip completely on the handlebar. Install while the glue is wet.

  • Page 22: Steering Knuckles

    CLEANING AND INSPECTING 1. Clean all knuckle components. Steering Knuckles 2. Inspect the bearing for pits, gouges, rusting, or pre- mature wear. REMOVING AND DISASSEMBLING 3. Inspect the knuckle for cracks, breaks, or excessive 1. Secure the ATV on a support stand to elevate the wear.

  • Page 23: Measuring/Adjusting Toe-Out

    733-559A NOTE: When measuring and adjusting, there  should be a normal operating load on the ATV (with- out an operator but with Arctic Cat approved acces- sories).

  • Page 24: Front Bumper Assembly

    2. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on Front Bumper Assembly the rear of the seat. The seat should automatically lock into position. REMOVING Lights Remove the four front cap screws securing the bumper support tubes to the frame.

  • Page 25: Running Lights

    KC431A KC434A 2. Turn the bulb socket assembly counterclockwise and remove from the housing. 3. Press in and turn the bulb counterclockwise to remove. Press in and turn clockwise to install the bulb. 4. Insert the bulb socket assembly into the housing and turn it clockwise to secure.
  • Page 26 BACK-UP LIGHTS 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming sur- The back-up lights are located outboard of the taillights- face (wall or similar aiming surface). brakelights. To replace the back-up light bulbs, use the following procedure.

  • Page 27: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure low 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 28: Engine/Transmission

    SPECIAL TOOLS A number of special tools must be available to the techni- Engine/Transmission cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description. This section has been organized into sub-sections which ...

  • Page 29: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3. Valves timing incorrect 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4.
  • Page 30 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 31: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service Top-Side Com- ponents, Left-Side Components, or Right-Side Compo- KC464A nents, the engine/transmission does not have to be...
  • Page 32 8. Remove the air inlet and outlet ducts from the CVT 14. From the top side, remove the engine coolant tem- housing. perature (ECT) sensor connector (C), fuel injector connector (D), temperature/manifold absolute pres- 9. Remove the cap screws securing the exhaust pipe to sure (TMAP) sensor connector (E), idle step control the cylinder head;...

  • Page 33: Top-Side Components

    Removing Top-Side Components A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft NOTE: Remove the spark plug, timing inspection  plug, and outer magneto cover; then using an appro- priate wrench, rotate the crankshaft to top-dead-cen- ter of the compression stroke. FI530B 1.
  • Page 34 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1354A 3. Remove the cap screw from the tension adjuster; then using a flat-blade screwdriver, relax the cam chain tension by rotating the adjuster screw clock- FI613 wise until it locks.
  • Page 35 FI617A FI619A 7. Remove the cam chain tensioner pivot bolt and 8. Remove the four cylinder head cap screws and wash- remove the chain tensioner; then remove the two ers. Note that the two cap screws on the right side of nuts securing the cylinder head to the cylinder.

  • Page 36: Servicing Top-Side Components

    FI621 FI625 14. Using Piston Pin Puller, remove the piston pin. C. Cylinder Account for the opposite-side circlip. Remove the D. Piston piston.  NOTE: Steps 1-10 in the preceding sub-section must NOTE: It is advisable to remove the opposite-side ...
  • Page 37 Cleaning/Inspecting Cylinder Head Cover NOTE: If the cylinder head cover cannot be trued,  the cylinder head assembly must be replaced. 1. Wash the cylinder head cover in parts-cleaning sol- vent. 2. Place the cylinder head cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper.
  • Page 38 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 39 CC995 CC127D 2. Measure the corresponding piston diameter at a point Measuring Piston Pin, Connecting Rod 8 mm (0.3 in.) above the piston skirt at a right angle Small End, and Piston-Pin Bore to the piston-pin bore. Subtract this measurement from the largest measurement in step 1.
  • Page 40 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair CAUTION the surface using a cylinder hone. Incorrect installation of the piston rings will result in 3. Place the cylinder on the surface plate covered with engine damage.
  • Page 41 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit ball hone. NOTE: To produce the proper 60° cross-hatch pat-  tern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute.

  • Page 42: Installing Top-Side Components

    Installing Top-Side Components A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and piston pin bore with engine oil; then install the piston on the connecting rod making sure there is a circlip on each side. GZ142 4. Loosely install the two nuts securing the cylinder to the right-side crankcase half.
  • Page 43 6. Place a new gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity. CAUTION Keep tension on the cam chain to avoid damaging the crankcase boss.
  • Page 44 CAUTION Care must be taken that the tab washer is installed cor- rectly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. 17. Apply red Loctite #271 to the first cap screw secur- ing the sprocket and tab washer to the camshaft;...

  • Page 45: Left-Side Components

    29. Install the spark plug and tighten securely; then install the timing inspection plug. Left-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
  • Page 46 FI541 FI596A 3. Remove two cap screws and the oil bolt securing the 6. Remove the magneto cover and account for two oil pressure relief line to the engine. Account for two alignment pins and the gasket. crush washers and an O-ring. D.

  • Page 47: Servicing Left-Side Components

    FI551A FI560 10. Remove starter idler gears and their respective 13. Remove the snap ring securing the output drive gear shafts; then remove the starter motor. Account for an to the output shaft and remove the gear noting that O-ring on the starter drive housing. the hub flange is directed toward the crankcase.
  • Page 48 FI569 FI576A 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING 1. Support the starter clutch gear in a press making sure to support the hub around the entire circumference;...
  • Page 49 FI580 FI590 3. Install the new stator coil assembly and secure with INSPECTING STATOR/MAGNETO three cap screws using a drop of red Loctite #271 on COVER ASSEMBLY each. Tighten to 8 ft-lb. 1. Inspect the stator for burned or discolored wiring, 4.

  • Page 50: Installing Left-Side Components

    FI594 MD1086 2. Clean the bearing bores in the housing and inspect 4. Install the shift detent cam arm and spring. closely for cracks or shiny areas indicating bearing 5. Install the gear shift shaft assembly and washer mak- movement. Replace the housing if any of the above ing sure to align the alignment marks.

  • Page 51: Right-Side Components

    8. Install the rotor/flywheel and secure with the flange nut. Tighten to 107 ft-lb. C. Magneto Cover D. Water Pump NOTE: Steps 1-8 in the preceding sub-section must  precede this procedure. 9. Install two alignment pins and place the magneto cover gasket into position.

  • Page 52: Removing Right-Side Components

    4. Remove the movable drive face and spacer. Account for the movable drive face rollers and outer drive Removing Right-Side face cover. Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the frame;...
  • Page 53 MD1094 MD1115 7. Remove the nut holding the driven pulley assembly; D. Centrifugal Clutch Assembly then remove the driven pulley assembly. E. Oil Pump Drive Gear F. Oil Pump Driven Gear NOTE: Steps 1-10 in the preceding sub-section must  precede this procedure.
  • Page 54 MD1016 MD1019 13. Remove the cam chain.  NOTE: Always use a new snap ring when installing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. FI630 14. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT ...

  • Page 55: Servicing Right-Side Components

    19. Remove the four cap screws securing the oil strainer cap; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. AT THIS POINT  To service center crankcase components only, proceed to Separating Crankcase Halves. Servicing Right-Side Components KC330 INSPECTING CENTRIFUGAL CLUTCH...

  • Page 56: Installing Right-Side Components

    DRIVEN PULLEY ASSEMBLY  NOTE: The driven pulley assembly is a non-service- able component and must be replaced as a complete assembly. Installing Right-Side Components A. Oil Strainer/Oil Pump 1. Place the oil strainer into position beneath the crank- case. Tighten the Phillips-head screws securely. MD1060 4.
  • Page 57 MD1017 MD1115 10. Tighten the clutch cover cap screws to 8 ft-lb. MD1018A 7. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand threads) (coated MD1117 11. Install the air intake plate. Apply red Loctite #271 to with red Loctite #271).

  • Page 58: Center Crankcase Components

    KC134 KC138 13. Slide the fixed drive face assembly onto the front shaft. 14. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 KC141 ...

  • Page 59: Separating Crankcase Halves

    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. Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes.
  • Page 60 FI659A FI653A 4. Remove the gear shift shaft (F) noting the inner and outer washers. FI661A 2. Remove the reverse idler assembly (B). Account for and note the location of the inner bushing (1), idler shaft (2), and outer washer (3). FI650A 5.

  • Page 61: Servicing Center Crankcase Components

    Correcting Backlash 7. Using Crankcase Separator/Crankshaft Remover with the appropriate crankshaft protector, remove the  NOTE: If backlash measurement is within the crankshaft. acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim.
  • Page 62 ATV-0105 CC290D 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal.
  • Page 63 ATV-1074 FI663 3. Zero the indicator and rotate the crankshaft slowly. CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications.  NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4.
  • Page 64 FI671 FI667 ASSEMBLING 4. Remove the splined washer; then remove the circlip securing the high-low sliding dog. Remove the slid- 1. With the high driven washer (1) on the countershaft, ing dog. install the high driven gear bushing (3), bearing (2), and gear (4) on the countershaft;...

  • Page 65: Assembling Crankcase Half

    3. Install the low driven bushing (10), bearing (9), and 5. Install the reverse dog on the shaft; then place the gear (11) on the countershaft; then install splined shift forks and shift shaft into position. washer (12). FI663 FI667A FI662 FI666 NOTE: The countershaft assembly is now ready to...
  • Page 66 MD1079 MD1024 2. Install and tighten the output shaft flange nut to 59 ft- 5. Install the key in the crank balancer shaft; then install lb. Using a punch, peen the nut. the gear and aligning the timing marks, slide the gear into place.
  • Page 67 FI662 FI646 10. Install the spacer (1), shaft (2), reverse idler gear, and washer (3). FI653 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crank- FI641A case.

  • Page 68: Joining Crankcase Halves

    FI659A FI639C 2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 3. From the right side, install the crankcase cap screws noting the location of the different-sized cap screws; then tighten only until snug. ...

  • Page 69: Installing Engine/Transmission

    6. In a crisscross pattern, tighten the 6 mm cap screws to 10 ft-lb. NOTE: Rotate the shafts back and forth to ensure  no binding or sticking occurs. AT THIS POINT  After completing center crankcase components, pro- ceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Com- ponents.
  • Page 70 11. Connect the air ducts to the CVT housing and tighten 14. Pour the specified amount of coolant into the radiator the clamps securely; then connect the air inlet tube to and the specified amount and grade of oil into the the throttle body and secure with the clamps.

  • Page 71: Fuel/Lubrication/Cooling

    Fuel/Lubrication/ Cooling ! WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leak- age, there should be no welding, smoking, open flames, etc., in the area. TROUBLESHOOTING FI691A 4. Disconnect the TMAP sensor connector, ISC con- 1.

  • Page 72: Gas Tank

    4. Turn the key to the OFF position and allow the gauge to shut off. Throttle Cable Free-Play To adjust the throttle cable free-play, follow this proce- dure. 1. Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster. KC450A NOTE: The reinstallable rivets may be easily ...

  • Page 73: Oil Filter/Oil Pump

    CLEANING AND INSPECTING 1. Clean all gas tank components with parts-cleaning solvent. 2. Inspect all hoses for cracks or leaks. 3. Inspect tank cap and tank for leaks, holes, and dam- aged threads. INSTALLING 1. Install the heat shield making sure the mounting studs lock in the bracket;...

  • Page 74: Liquid Cooling System

    Checking/Filling 1. Locate the coolant reservoir on the right side behind the radiator. 2. Remove the cap and fill with the appropriate coolant until coolant level is between the LOW and FULL lines. Do not overfill. KC195A KC396A 3. Install the cap on the reservoir. CAUTION After operating the ATV for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check...

  • Page 75: Water Pump

    2. Place the radiator with grommets and collars into 2. Fill the cooling system to the recommended level position on the frame; then install the cap screws. with antifreeze. Check for leakage. Tighten securely. WATER PUMP 3. Install the upper and lower coolant hoses, fill hose, ...

  • Page 76: Troubleshooting

    FI538A FI530 2. Connect the coolant hoses to the water pump and 3. Place the footrest into position on the frame and secure with the clamps. Tighten securely. loosely secure with four cap screws; then secure the front and rear fenders to the footrest with the four torx-head cap screws.

  • Page 77: Electrical System

    Maintenance Charging TESTING ELECTRICAL COMPONENTS  NOTE: Arctic Cat recommends the use of the All electrical tests should be made using the CATT II or CTEK Multi US 800 or the CTEK Multi US 3300 for the Fluke Model 77 Multimeter. The CATT II can return battery maintenance charging.

  • Page 78: Ignition Switch

    1. Set the meter selector to the DC Voltage position.  NOTE: Arctic Cat recommends the use of the 2. Connect the red meter lead to the red wire; then con- CTEK Multi US 800 or the CTEK Multi US 3300 for nect the black meter lead to ground.

  • Page 79: Ignition Coil

    7. The meter must show less than 1 ohm. Ignition Timing NOTE: If the meter shows more than 1 ohm of resis-  tance, replace the switch. The ignition timing cannot be adjusted; however, verify- ing ignition timing can aid in troubleshooting other com- Ignition Coil ponents.
  • Page 80 RESISTANCE (Engine Stop) 2. Connect the red tester to the orange wire; then con- nect the black tester lead to ground. 1. Set the meter selector to the OHMS position. 3. The meter must show battery voltage. 2. Connect the one lead to the brown/lavender wire; then connect the other tester lead to the black/white NOTE: If the meter shows no battery voltage, trou- ...

  • Page 81: Fan Motor

    3. Connect the red tester lead to the white/green wire on the harness side of the connector. Fan Motor 4. Turn the ignition switch to the RUN position. 5. The meter must show battery voltage.  NOTE: If the meter shows other than specified, check the harness, connector, main relay, and battery connections.

  • Page 82: Lights

    6. Select the 4WD position on the drive select switch; NOTE: If battery voltage is not shown in any test,  then connect the red tester lead to the white/green inspect the fuses, battery, main wiring harness, con- wire in the supply harness. The meter must show 0 nectors, or the left handlebar switch.

  • Page 83: Power Distribution Module (Pdm)

    KC279 KC466A If there is any type of related electrical system failure, always check the fuses first.  NOTE: To remove a fuse, compress the locking tabs on either end of the PDM cover and lift off; then remove the applicable fuse. KC280 Voltage 1.

  • Page 84: Efi Sensors/Components

    EFI Sensors/Components FUEL INJECTOR Component data can be tested using the CATT II. Utilize the Test screen. Voltage Remove the connector from the fuel injector. Place the KC518A red meter lead to the orange wire and black meter lead to 2.
  • Page 85 The electric fuel pump and fuel level sensor are not ser- viceable components. If either component fails, it must be replaced. Testing ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.

  • Page 86: Speed Sensor

    Inspecting 4. Connect the wires and gasline hose; then connect the negative battery cable and turn the ignition switch to AT THIS POINT  the ON position. Note that the fuel pump runs momentarily and the fuel gauge indicates the proper If the pump has failed earlier test and must be replaced, fuel level.

  • Page 87: Tilt Sensor

    6. Slowly move the ATV forward or backward; the meter must show 0 and >12 volts alternately. NOTE: If the sensor tests are within specifications,  the speedometer/LCD gauge must be replaced (see Speedometer/LCD Gauge). To replace a speed sensor, use the following procedure. 1.
  • Page 88 KC416A KC517 4. Tilt the sensor 60° or more to the left and right  NOTE: Prior to testing the TPS, inspect the three- observing the meter. The meter should read 3.0-8.0 wire plug connector on the main harness and the DC volts after approximately one second in the tilted three-pin plug on the TPS for contamination, broken position.

  • Page 89: Rpm Limiter

    2. Adjust the TPS until the correct reading is obtained; 4. Turn the key to the OFF position and allow the gauge then tighten the screw securely. Open and close the to shut off. throttle and determine the reading at idle the correct voltage.

  • Page 90: Starter Relay

    NOTE: The ignition switch must be in the ON posi-  tion, the engine stop switch in the RUN position, and the shift lever in the NEUTRAL position. 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the starter terminal; then connect the black tester lead to ground.

  • Page 91: Efi Diagnostic System

    NOTE: If the throttle body, ECM, TPS, or ISC are  replaced, the EFI system must be synchronized. Use the following procedure. 1. With the key off, depress throttle lever to Wide Open Throttle (WOT). 2. Place the ignition key in the ON position and wait for 10 seconds.
  • Page 92 Coolant (COOL) Diagnostic Mode Tachometer (tACH) Diagnostic Mode EFI 003 EFI009 Display: Engine coolant temperature as measured by the Display: Engine RPM ECT sensor. DTC: P0336, P0337, P0339 DTC: P0116, P0117, P0118, P0119 Usage: Verify engine speed signal from the following. Usage: Monitor coolant temperature to verify the follow- 1.
  • Page 93 Display: % of TPS (0% closed, 95-100% WOT). NOTE: After engine has been running, IAT read-  ings will be higher than outside air temperature due DTC: P0121, P0122, P0123 to engine and engine compartment heat as well as intake manifold heating. Usage: Verify TPS signal and adjust throttle cable.
  • Page 94 Code Fault Description Possible Cause Fault Recovery P0107 MAP Sensor Circuit Low/SG/Open Sensor or interconnect harness shorted to chassis ground Correct condition* P0108 MAP Sensor Circuit High/SP Sensor or interconnect harness shorted to battery power Correct condition* P0112 Intake Air Temp Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition* P0113...

  • Page 95: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Alternator defective 3. Replace stator coil assembly 4. ECM defective 4. Replace ECM 5. Crankshaft Position Sensor defective 5.

  • Page 96: Drive System

    Drive System GENERAL INFORMATION 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.) All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code.

  • Page 97: Front Differential

    Front Differential REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the drain plug and drain the gear lubricant AG925 into a drain pan;...
  • Page 98 KC314 KC291A 9. Support the axle to not allow it to drop or hang. Disassembling Input Shaft CAUTION NOTE: This procedure can be performed on a rear  gear case; however, some components may vary from The axle must be supported. If the axle is allowed to model to model.
  • Page 99 CD106 AF983 3. Using a side-cutter (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing. AF984 CD107 5. Using the Multi-Seal Remover, remove the input shaft seal.
  • Page 100 AF994 CD112 2. Install the input shaft seal making sure it is flush with 5. Using a new O-ring lubricated with grease, install the edge of the housing. the front drive actuator and secure with the cap screws. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulfide Grease.
  • Page 101 5. Unstake the lock collar; then using the 48 mm Inter- nal Hex Socket, remove the lock collar securing the pinion gear assembly. CAUTION Failure to completely remove the staked material from the lock collar will result in the destruction of the threads in the gear case housing.
  • Page 102 2. Install the ring gear with shim in the gear case; then while holding the pinion stationary, rock the ring gear forward and back to determine if any backlash exists. If no backlash exists, install a thicker shim and recheck. CC879 ...
  • Page 103 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness. NOTE: Once proper backlash and end play are  established, the gear case can be assembled (see Assembling Differential Assembly in this sub-section). RING GEAR/THRUST BUTTON Removing Remove the thrust button from the gear case cover (left- hand threads).
  • Page 104 4. If clearance is not as specified, repeat steps 1 and 2 NOTE: Grease can be applied to the O-ring for ease  using thicker (clearance too great) or thinner (clear- of assembling. ance too small) until correct specification is reached. 4.
  • Page 105 CD110 CC887 Removing Needle Bearing Installing Needle Bearing 1. Apply green Loctite #609 to the outside of a new NOTE: Removing the needle bearing is rarely nec-  bearing; then place the new bearing into the housing. essary. Avoid removing the needle bearing unless the bearing is clearly damaged.
  • Page 106 CC890 CC900 4. Place a punch on the edge of the lock collar in the oil 3. Using a press, install the new bearing into the hous- gallery area; then using a hammer, stake the lock col- ing. lar to ensure that the collar will remain securely tightened.

  • Page 107: Drive Axles

    4. Install the wheels and using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/ chrome nuts). 5.
  • Page 108 7. Remove the ATV from the support stand and release the brake lever lock. INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steering knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tight- ened to 35 ft-lb.

  • Page 109: Rear Gear Case

    Rear Gear Case REMOVING REMOVING 1. Remove both of the rear drive axles. 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. 2. Remove the four cap screws securing the engine out- put shaft to the rear gear case input flange. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 110: Hand Brake Lever/Master Cylinder Assembly

    KC283 AF637D 6. Tighten the hub nut (from step 4) to 200 ft-lb; then 2. Place an absorbent towel around the connection to install and spread a new cotter pin making sure each absorb brake fluid. Remove the banjo-fitting bolt side of the pin is flush to the hub nut.

  • Page 111: Hydraulic Brake Caliper

    Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death. REMOVING/DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel;...
  • Page 112 PR713A PR715 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury.
  • Page 113 PR719C 4. Install the caliper onto the caliper holder making sure PR238 the caliper and holder are correctly oriented. NOTE: It is very important to apply silicone grease  to the O-rings and caliper bores prior to assembly. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock”...

  • Page 114: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.

  • Page 115: Suspension

    Suspension Front A-Arms REMOVING The following suspension system components should be 1. Secure the ATV on a support stand to elevate the inspected periodically to ensure proper operation. front wheels; then remove the wheels. A. Shock absorber rods not bent, pitted, or damaged. ! ! WARNING B.

  • Page 116: Rear A-Arms

    9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut. 11. Install the wheels and using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/ chrome nuts).

  • Page 117: Wheels And Tires

    ! WARNING 2. Inspect the A-arm for bends, cracks, and worn bush- Use only Arctic Cat approved tires when replacing tires. ings. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of 3.

  • Page 118: Troubleshooting

    NOTE: If repair is needed, 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 Front Wheel Alignment). 4.
  • Page 119 NOTES...
  • Page 120 ©2015 Arctic Cat Inc. Effective Date: September 2015 Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-667...

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