Arctic Cat 700 DIESEL 2015 Service Manual
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Arctic Cat 700 DIESEL 2015 Service Manual

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S E R V I C E M A N U A L
700 DIESEL
www.arcticcat.com

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  • Page 1 S E R V I C E M A N U A L 700 DIESEL www.arcticcat.com...
  • Page 2 This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The proce- dures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information ............2 Diesel Fuel Injection System........106 General Specifications..........2 Lift Pump..............106 Unit Injectors ............107 Torque Specifications ..........2 Torque Conversions (ft-lb/N-m)........3 Injector Timing ............107 Fuel Filter ............... 107 Fuel - Oil - Lubricant........... 3 Genuine Parts.............

  • Page 4: General Information

    CYLINDER, PISTON, AND RINGS General Information Bore x Stroke 75 x 77.6 mm Piston Ring End Gap - Installed (min) 0.25 mm Piston Ring Groove Width (1st) 0.090-0.125 mm (2nd) 0.050-0.085 mm  NOTE: Some photographs and illustrations used in (3rd) 0.040-0.075 mm this manual are used for clarity purposes only and...

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

    Fuel - Oil - Lubricant Drive Clutch Flywheel/PTO Shaft Movable Drive Face* Fixed Drive Hub Oil Pump Engine Block  NOTE: Arctic Cat recommends the use of genuine Output Shaft* Output Shaft Coupler Arctic Cat lubricants. Output Shaft Nut* Output Shaft Starter...

  • Page 6: Genuine Parts

    RECOMMENDED TRANSMISSION When replacement of parts is necessary, use only genuine LUBRICANT Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illus- The recommended transmission lubricant is SAE trated Parts Manual for the correct part number, quantity, approved 80W-90 hypoid.

  • Page 7: Preparation After Storage

    8. Tighten all nuts, bolts, cap screws, and screws mak- will assure many miles and hours of trouble-free riding. ing sure all calibrated nuts, cap screws, and bolts are Arctic Cat recommends the following procedure to pre- tightened to specifications. pare the ATV.

  • Page 8: Periodic Maintenance/Tune-Up

    Periodic Maintenance/ Tune-Up Tighten all nuts, cap screws, screws, and bolts. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all cali- brated nuts, cap screws, screws, and bolts are tightened to specifications.

  • Page 9: Valve Clearance

    Muffler/Spark Arrester The muffler has a spark arrester which must be periodi- cally cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the fol- lowing procedure. ! WARNING Wait until the muffler cools to avoid burns. 1.

  • Page 10: Engine Rpm (Idle)

    CF297A DE017A 3. Tighten the jam nut against the throttle cable adjuster 4. Remove the right-side engine cover. securely; then slide the rubber boot over the adjuster. 5. Using a suitable filter wrench, remove the oil filter.  NOTE: Clean up any excess oil after removing the Engine RPM (Idle) filter.

  • Page 11: Transmission Lubricant

    DE519D DE026A 11. Install the oil level stick and push in firmly. 3. Remove the transmission drain plug from the bottom of the transmission and drain the lubricant into a drain pan. 12. Remove the oil level stick; the engine oil level should be above the illustrated “L”...

  • Page 12: Tires

    TIRE INFLATION PRESSURE To check lubricant, remove the level plug; the lubricant level should be visible at the threads. If low, add SAE Front and rear tire inflation pressure should be 0.49 kg- approved 80W-90 hypoid gear lube as necessary. cm²...

  • Page 13: Frame/Welds/Racks

    2. With the ignition switch in the ON position, loosen jam nut (A) (left-hand threads); then loosen jam nut (C) and with the shift lever in the reverse position, adjust the coupler (B) until the transmission is in reverse and the (R) icon appears on the LCD. CF295A CF258A 3.
  • Page 14 PR377C PR376B  NOTE: During the bleeding procedure, watch the  NOTE: The brake pads should be replaced as a set. reservoir/sight glass very closely to make sure there 4. To replace the brake pads, use the following proce- is always a sufficient amount of brake fluid. If low, dure.

  • Page 15: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both hydraulic and auxiliary) must be bur- nished to achieve full braking effectiveness. Braking dis- tance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
  • Page 16 6. Push the V-belt down between the sheaves of the driven pulley approximately one inch; then making sure not to dislocate the one-way clutch from the fixed drive hub, squeeze the belt together and remove from the drive clutch. DE093A DE098A INSTALLING 1.

  • Page 17: Fuel Filter

    3. Pinch the V-belt together near its center and slide the movable drive face onto the drive hub. Secure the Fuel Filter drive face with a nut (threads coated with red Loctite #271). Tighten the nut to 85 ft-lb. This diesel-powered ATV is equipped with a high effi- ciency fuel filter.

  • Page 18: Front Body Panel/Side Panels

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.
  • Page 19 7. Remove the shift knob retaining pin and remove the shift knob; then remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. CD765A  NOTE: It may be necessary to rotate the body panel to the right to align the opening with the handlebar.

  • Page 20: Rear Body Panel/Rack

    4. Install one cap screw and flange nut and four plastic rivets on each side to secure the front fenders to the footwells. Tighten the flange nuts securely.  NOTE: If the footwells have been removed, see Footrests in this section. 5.

  • Page 21: Steering Post/Tie Rods

    CD690A CD759 3. Install one shoulder screw and three plastic rivets (on 2. Remove the reinstallable rivets securing the radiator each side) to secure the front of the rear body panel access cover and remove the cover. to the footwells. CD666 3.
  • Page 22 CLEANING AND INSPECTING 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3.

  • Page 23: Handlebar Grip

    INSTALLING  NOTE: If the slots do not align with the holes in the tie rod ends, tighten the nuts just enough to allow  NOTE: Before installing a grip, use contact spray or installation of the cotter pins. alcohol to clean the inside of the grip and the handle- bar of glue residue, oil, or any other contaminant.
  • Page 24 INSTALLING CAUTION 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV. 3. Remove the snap ring and pivot pin securing the brake lever to the master cylinder housing;...

  • Page 25: Throttle Control

    INSTALLING Throttle Control 1. Place the return spring into the throttle control; then place the bushing and actuator arm into position. Secure with the cap screw, lock washer, and washer. REMOVING 1. Remove the two machine screws securing the throt- tle control to the handlebar.

  • Page 26: Lcd Gauge

    3. Check shift lever adjustment (see Periodic Mainte- nance/Tune-Up section); then tighten jam nut(s) securely. 4. Install the left-side splash panel. LCD Gauge REPLACING 1. Remove the two reinstallable rivets securing the instrument pod; then remove the ignition switch retaining ring. PR287A 2.

  • Page 27: Measuring/Adjusting Toe-Out

    2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft- PR257 7. Secure the brake caliper to the knuckle with new “patch-lock” cap screws. Tighten to 20 ft-lb. AF760D 3.

  • Page 28: Front Rack

    DE047A CF344A 4. Adjust the handlebar direction until the two measure- CAUTION ments are equal; then secure the handlebar to the rear rack using tie-down straps. Always use a wrench to hold the tie rod in place when loosening either of the jam nuts or damage to the boots ...

  • Page 29: Footrests

    INSTALLING 2. Remove the through-bolt and lock nut securing the bumper to the frame; then remove the bumper. 1. Secure the footrests to the frame with four cap CLEANING AND INSPECTING screws and two flange nuts; then tighten securely. 1. Clean all bumper components. 2.

  • Page 30: Taillight Assembly

    ! WARNING Taillight Assembly Do not attempt to remove the bulb when it is hot. Severe burns may result. To replace the headlight bulb, use the following proce- REMOVING dure. 1. Unplug the three-prong connector and free the tail- 1. Remove the wiring harness connector from the back light wiring harness from the frame.
  • Page 31 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming sur- face (wall or similar aiming surface).  NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. 2.

  • Page 32: 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 33: Engine/Transmission

    0444-233 removed from the frame. Unit Injector Retainer Nut Tool 0444-227  NOTE: Arctic Cat recommends the use of new gas- Pre-Combustion Chamber Ring Nut Tool 0444-235 kets, lock nuts, and seals and lubricating all internal Pre-Combustion Chamber Removal Tool...

  • Page 34: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service/replace left- side components, right-side components, and/or top- DE066A side components, the engine/transmission does not have to be removed from the frame.
  • Page 35 CAUTION The fuel rail connections are easily bent. Use care when removing the hose clamps and hoses. 13. Disconnect the wire connectors from the temperature sensor, oil pressure sensor, gear position switch con- nector, and voltage regulator; then disconnect the starter solenoid, glow plug power wire, and the alter- nator positive wire.
  • Page 36 DE494A DE086A 14. Apply the hand brake and engage the brake lever 19. Remove the cap screw and nut from the upper right lock; then remove the cap screws from the front engine mount. Account for a flat washer. drive coupler. DE088A 20.
  • Page 37 21. Remove the transmission level stick mount and 5. Drain the transmission lubricant into a suitable con- housing; then disconnect the throttle cable from the tainer; then disconnect the transmission vent hose, throttle control arm and unthread the throttle cable gear shift position switch connector, speed sensor housing.

  • Page 38: Top-Side Components

    AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure. SPEED GOVERNOR Removing/Disassembling 1.
  • Page 39 4. Disconnect the high-low speed spring assembly from the throttle control arm; then remove the intake man- ifold/throttle control housing. Account for a gasket. DE245A DE258A 5. Rotate the crankshaft in the direction of rotation approximately 90° from TDC. DE277 8.
  • Page 40  NOTE: Do not loosen or remove screws (D) or (E) or fuel delivery equalization will have to be performed. DE252A DE291A DE285A DE327 DE286A CAUTION Do not break the seal or turn the torque limiter adjuster DE282 screw. Severe engine damage could occur. 11.
  • Page 41 3. Inspect the control spool, thrust bearing, and thrust washer for scoring, excessive wear, or missing bear- ing rollers. DE254 Inspecting 1. Inspect the flyweight assembly for loose pins, worn DE278A contact points, or excessive pivot point wear. 4. Coat all serviceable parts with clean engine oil. Assembling/Installing 1.
  • Page 42 6. Place control spool, thrust bearing, and thrust washer into the governor flyweight assembly and secure the flyweights with a rubber band; then place assembly onto the camshaft with a new O-ring. Make sure to remove the rubber band. DE258A DE279A DE248A 4.
  • Page 43 DE246A DE262 7. Using a new O-ring, coat the flange of the camshaft 10. Install the timing belt (see Left-Side Components in bearing retainer and the camshaft support housing this section). with clean engine oil and install into the cylinder 11.
  • Page 44 CAMSHAFT/ROCKER ARMS Removing 1. Remove the timing belt (see Left-Side Components in this section). 2. Remove the front rack and front body; (see Steering/ Frame/Controls) then remove the air filter assembly and mounting bracket, and air diverter with ducts. DE294A 6.
  • Page 45 DE275A DE260C DE404A DE529 9. Place a holding pin into the injector pump barrel; 11. Using an appropriate holding tool, remove the cap then rotate the camshaft until the second injector is screw securing the camshaft drive pulley to the cam- fully compressed and install a holding pin.
  • Page 46 DE246A DE299A 13. Remove the governor control spool, thrust bearing, CAUTION and thrust washer keeping all components in order of Make sure to support the camshaft while the journals disassembly. are pulled clear of the journal bores or damage to jour- nal bores may occur.
  • Page 47 DE524 DE522 5. Inspect rocker arms, camshaft followers, and rocker shaft for excessive wear, broken or scored rollers, or cracked rocker arm shaft supports. DE523 7. Using a micrometer, measure and record camshaft intake, exhaust, and injection lobe height. Measure- ments must not be less than minimum specifications.
  • Page 48  NOTE: If the rocker arm assembly is to be disas- sembled, label all rocker arms for installing purposes. If the rocker arms are mixed up, the complete over- head must be adjusted. 9. After labeling rocker arms and supports, remove components from the rocker arm shaft.
  • Page 49 DE278A DE537 6. Using a new O-ring, install the camshaft support housing and tighten the cap screws to 7 ft-lb. DE531A 5. Apply clean engine oil to the governor assembly and install on the camshaft; then hold the flyweight assembly and remove the rubber band. Install a new DE245A 7.
  • Page 50 DE529 DE451 13. Using a crisscross pattern, tighten the Allen-head cap screws to 6.5 ft-lb; then tighten the two “tamper- proof” torx-head cap screws to 6.5 ft-lb. 14. Connect the fuel hoses to the fuel rail; then connect the crankcase breather hose. DE571 9.
  • Page 51 UNIT INJECTORS 7. Remove eight standard torx-head cap screws from the valve cover; then using Torx-Head Screwdriver - Removing #30, remove the two “tamper-proof” torx-head cap screws. 1. Remove the front rack and front body panel (see Steering/Frame/Controls). 8. Remove four Allen-head machine screws securing the fuel rail to the unit injectors;...
  • Page 52 Proper servicing of fuel injection components requires a number of special instruments, special training, and an extremely clean environment (clean room); therefore, DE566A Arctic Cat recommends injector service be performed by a qualified diesel injection service facility. Installing 1. Thoroughly clean the injector bores in the cylinder...
  • Page 53 DE570A DE569A 4. Clean the fire ring sealing surface in the cylinder head taking care not to damage the pre-combustion cup ring nut. DE570  NOTE: A small amount of lithium grease applied to the washers will aid in keeping them in place on the DE567B injector while installing.
  • Page 54 12. Install the fuel spring. DE329 10. Rotate the engine clockwise to compress the injector DE292 push rod sufficiently to remove the hardened pin; AT THIS POINT then repeat for the second injector.  If injectors were serviced, static injector timing must be set (see Top-Side Components in this section).

  • Page 55: Valve Clearance Adjustment

    20. Install the front body panel, front rack, and seat (see Steering/Frame/Controls). VALVE CLEARANCE ADJUSTMENT  NOTE: If the engine has been disassembled, pro- ceed to step 4. If the primary objective is to adjust the valves, use the following procedure. 1.
  • Page 56 DE405B DE429A 7. When proper clearance is attained, tighten the jam  NOTE: The valve cover has two “tamper-proof” nut (A) while holding the adjuster (B); then tighten torx-head cap screws that can be removed by using the jam nut securely and check clearance (C). Torx-Head Screwdriver - #30.
  • Page 57 11. Install the front body panel; then install the front rack and splash panels (see Steering/Frame/Controls). STATIC INJECTOR TIMING To set static injector timing, use the following procedure. 1. Remove the valve cover and fuel rail (see Unit Injec- tors in this sub-section). 2.
  • Page 58 DE562B DE446 C. While watching the bleed hose, turn the adjustment 7. Observe the alignment of reference mark (D) and the screw counterclockwise until fuel flow starts (A); 13° BTDC mark (B). then clockwise until fuel flow stops (B). DE561A DE562C ...

  • Page 59: Cylinder Head Assembly

    DE534B DE240A DE405A 11. Install the valve cover using a new gasket and new DE275A oil return boot. Tighten the Allen-head cap screws to 7. Turn the camshaft drive pulley until the camshaft and 6.5 ft-lb using a crisscross pattern; then tighten the rocker arms are “unloaded”...
  • Page 60  NOTE: It is recommended to keep all individual components in a set, such as valve, valve spring, valve keepers, spring holders, and retainers to aid during assembling. DE584 10. Remove the six cap screws securing the cylinder head to the engine block and remove the cylinder head assembly.
  • Page 61 DE324 DE321 7. Remove the exhaust manifold; then remove the ther- mostat housing. Cleaning and Inspecting Cylinder Head/Valves 1. Thoroughly clean the cylinder head in a non-caustic solvent; then dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air.
  • Page 62 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 surface is worn, the valve must be replaced.
  • Page 63 DE301 DE326A 5. Slowly release the valve spring compressor while making sure the valve keepers engage the groove in the valve stem. DE321A 3. Insert the Pre-Combustion Chamber Index Tool into the glow plug bore while slightly shifting the cham- ber until the alignment tool properly engages the DE301A opening in the chamber;...
  • Page 64 DE311A DE386 5. Remove the Pre-Combustion Chamber Index Tool C. Use steps A and B to measure and record piston and repeat steps 2-4 for the second pre-combustion protrusion on the other piston. chamber; then install the glow plugs and tighten to D.
  • Page 65 DE341A DE577A 2. Make sure the cylinder deck surface is clean and free 5. Clean the threads of the cylinder head bolts on a wire of all oil, grease, varnish, or coolant. wheel; then measure the length of the bolt. Bolt length must not exceed 91 mm.

  • Page 66: Left-Side Components

    11. Adjust the valves (see Top-Side Components in this section). 12. Check and adjust static injector timing (see Top-Side Components in this section). 13. Install the engine and transmission (see IInstalling Engine/Transmission in this section). Left-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to DE211A 6.
  • Page 67 DE269A DE273 9. Check that the reference mark (C) on the timing belt 2. Inspect the drive and driven pulleys for wear, burrs, drive pulley aligns with the reference mark (D) on or dirt build-up between cogs. Clean and remove the oil pump housing.
  • Page 68 3. Install the Timing Belt Tensioning Tool on the timing belt tensioner tab; then using a suitable torque wrench, position the handle 90° to the tensioner tab and apply 14.5 ft-lb of torque. Tighten the timing belt idler nut securely. DE275B B.

  • Page 69: Water Pump

    3. Remove the lower radiator hose and the coolant bypass hose from the water pump; then remove four cap screws securing the water pump and remove the water pump. 4. Thoroughly clean all gasket material from the engine block and water pump. Servicing ...
  • Page 70 3. Remove the screws securing the oil pump to the engine block; then tap lightly on the oil pump with a plastic mallet to loosen the gasket and remove the oil pump assembly from the crankshaft. DE237  NOTE: If there is a groove worn in the crankshaft where the seal contacts, press the seal into the bore an additional 2 mm (0.080 in.).
  • Page 71 DE266A DE519B 4. Lubricate the crankshaft and crankshaft seal with a 3. Loosen the alternator adjuster cap screw (A) and the liberal amount of engine oil; then install the oil pump pivot bolt (B); then remove the alternator drive belt. onto the crankshaft being careful not to damage the oil seal.

  • Page 72: Right-Side Components

    DE103B DE099A 3. Holding tension on the belt, tighten the adjuster cap 3. Remove two cap screws securing the starter to the V- screw securely; then remove the pry and tighten the belt housing; then remove the starter. pivot bolt securely. 4.
  • Page 73 Inspecting 1. Inspect the V-belt housing for cracks, elongated mounting hoses, or loose alignment pins. 2. Inspect the flywheel/ring gear assembly for worn or broken teeth, cracks, or elongated mounting holes. Replacing Ring Gear To replace the ring gear, use the following procedure. 1.
  • Page 74 DE102A DE119A 4. Remove the shift shaft housing. Account for a gas- TRANSMISSION ket. Disassembling Gear Case 5. Remove the shift shaft, noting the match marks on the drive and driven gear plates. Account for a 1. Remove the gear position switch. Account for two washer on each end.
  • Page 75  NOTE: For steps 10-15, refer to illustration DE663B. DE126A 8. From the right side, remove the cap screws securing DE663B the transmission halves together; then lay the trans- 10. Remove the output driveshaft assembly (A). Account mission on a suitable bench with the right side down. for the bearing alignment C-ring in the bearing boss next to the output driven bevel gear.
  • Page 76 DE139 DE655A 14. Remove the countershaft assembly (E). Account for 17. Using an appropriate seal removal tool, remove any a thrust washer on each end noting the different damaged seals from the transmission case. sizes. 18. Remove the snap ring securing the output drive bear- ing in the right-side case;...
  • Page 77 DE146 DE150A 20. Remove the retaining nut from the front driveshaft and remove the front drive yoke. Account for a washer, seal, bearing, and shim. DE191A 23. Remove the thrust washer and countershaft drive gear from the opposite end of the countershaft. DE147 21.
  • Page 78 DE152 DE184 27. Remove the low gear. Account for a washer and the low gear bearing and bushing. DE153 25. Remove the snap ring securing the reverse gear; then remove the reverse gear. Account for a thrust washer DE155 and the reverse gear bearing and bushing. Inspecting 1.
  • Page 79 2. Inspect all shift dogs for chips, rounded dogs, worn 4. Inspect roller bearings for chipping, missing rollers, splines, or discoloration. or discoloration. DE178 DE162 DE185 5. Inspect drive and driven bevel gears for proper tooth DE177 3. Inspect all idler gears, bushings, thrust washers, and contact, chipping or discoloration of gear teeth, worn shafts for abnormal wear, discoloration, chipping, or or chipped splines, and bearing smoothness.
  • Page 80 7. Inspect shift forks for excessive wear, galling of wear surfaces, or discoloration. DE128 11. Inspect bearings for discoloration, flaking, or rough- ness and binding when turning. DE165 8. Inspect shift cam assembly for worn cam grooves or 12. Inspect and thoroughly clean all bearing pockets, broken springs.
  • Page 81 DE158B DE186 2. Install the low driven gear onto the bearing with the 5. Install the reverse shift dog and splined bushing onto shift dog slots directed toward the fine-splined sec- the shaft; then secure with a snap ring. tion of the countershaft; then secure with a splined washer and lock washer.
  • Page 82 8. Install the high driven gear thrust washer, bushing, and bearing; then install the high driven gear and thrust washer. DE659A 1. Place the spacer on the output shaft; then press the secondary output driven gear onto the output shaft until it firmly contacts the spacer.
  • Page 83 2. Install the secondary driven output shaft into the gear case and seat firmly. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear. 4. While rocking the drive bevel gear back and forth, note the maximum backlash reading on the gauge.
  • Page 84 DE170 DE192A 3. Install the assembled countershaft assembly taking care to position a washer on each end. DE169 2. Install the reverse idler gear making sure to install a washer on each side of the gear; then install the input DE142 driveshaft.
  • Page 85 5. Install the high/low shift fork and engage the fork in the high/low cam slot in the gear shift shaft; then install the shift fork shaft. DE133D DE136A 6. Install the secondary output driveshaft aligning the front bearing alignment ring with the groove in the gear case and rotate the bearing to locate the bearing anchor pin in the slot;...
  • Page 86 9. Install the speed sensor trigger and secure with the circlip; then install the speed sensor housing and secure with the cap screws. Tighten securely. DE119 12. Apply Three Bond Sealant to the secondary output shaft bearing housing; then install on the transmis- sion and tighten securely.

  • Page 87: Center Components

    14. Install the left and right transmission mounting brackets and tighten the cap screws securely. The transmission is now ready to be installed on the V- belt housing. Center Components  NOTE: This procedure cannot be done with the engine in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure.
  • Page 88 11. Rotate the crankshaft carefully until the second con- necting rod is at BDC; then using a large wooden dowel or hammer handle, carefully push against the first connecting rod until the piston/connecting rod assembly is free of the cylinder bore. ...
  • Page 89 13. Remove the two cap screws from the second con- necting rod cap and remove the cap. Account for one bearing insert. DE335C 18. Lightly rock the bearing caps in the saddles while applying pressure away from the crankshaft until the bearing cap is free of the engine block.
  • Page 90  NOTE: The crankshaft should be supported in the three main bearing journal locations or stood on the flywheel end. Do not drop or strike the crankshaft. 20. Set main bearing caps with inserts into the main bearing saddles and install cap screws. Finger tighten only.
  • Page 91  NOTE: Planing the engine block is not recom- mended as it will directly affect piston-to-cylinder head clearance. To determine if the cylinder deck can be planed, use the following procedure. A. Determine the maximum cylinder deck variation B. Add the deck variation (V ) to the piston protrusion ) determined during removing (V ) to deter-...
  • Page 92 DE398 DE363 DE356 DE362 10. Wash the crankshaft, connecting rods, and oil pan  NOTE: Undersized connecting rod and main bear- and cover in parts-cleaning solvent; then dry with ings are available in 0.25 mm (0.010 in.) and 0.50 mm compressed air.
  • Page 93 16. Subtract the crankshaft journal measurement from the corresponding main bearing bore. The clearance must be within specifications. DE376 14. Install the main bearing caps and tighten to 44 ft-lb; then being careful not to mar the inserts, measure the main bearing bores using an appropriate inside DE609A micrometer/snap gauge.
  • Page 94 DE352 DE623 19. Using an appropriate inside micrometer, measure the 22. Examine the piston pin bushing for galling or discol- inside diameter of the connecting rod bearing insert. oration. If either condition exists, replace the bushing It must be within specifications or the bearings or or connecting rod.
  • Page 95  NOTE: Replacement pistons are only supplied as class A. Class B and C are reserved for production engines. Replacement pistons are available over- sized by 0.50 mm (0.020 in.) and 1.00 mm (0.039 in.) and are supplied with piston rings. CAUTION Do not attempt to use standard rings on oversized pis- tons or oversized rings on standard pistons.
  • Page 96 DE431 DE377A 4. Apply a liberal amount of clean engine oil to the 7. Remove the Main Bearing Seal Installation Tool or crankshaft main bearing journals and the main bear- shim stock; then install the main bearing cap screws. ing saddles; then carefully install the crankshaft into the engine block.
  • Page 97 10. Rotate the crankshaft to make certain that no binding A. Place the oil expander ring in the 3rd (bottom) exists. ring groove; then install the oil scraper ring over the expander making sure the oil scraper ring end 11. If pistons were removed from connecting rods, gap is not directly in line with the expander spring install the pistons onto the connecting rods making ends.
  • Page 98 DE392 DE393A 17. Rotate the crankshaft so the crankshaft rod journal corresponding to the piston being installed is at bot- tom-dead-center (BDC). DE390 CAUTION NEVER force the piston into the cylinder. If sudden DE335 resistance is encountered, remove and start over as 18.
  • Page 99 DE437 DE410 27. Install new O-rings on the oil sump and return pipes; then apply oil-soluble grease on the O-rings and place the oil pan into position. DE439 22. Repeat steps 15-21 for the second piston. 23. Install the oil pump (see Fuel/Lubrication/Cooling). DE596A 24.

  • Page 100: Installing Engine/Transmission

    Installing Engine/ Transmission  NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV.  NOTE: If the engine/transmission was removed as an assembly, proceed to Engine/Transmission in this sub-section.
  • Page 101 DE113A DE479 3. Install the engine-to-transmission mounting plate and cap screws; then tighten the cap screws from step 2 and from this step to 35 ft-lb. DE488 6. Secure the driven pulley with a flat washer and nut (threads coated with green Loctite #609); then tighten the nut to 125 ft-lb.
  • Page 102 DE084B DE087A 3. Align and connect the rear propeller shaft to the rear 6. Install the cap screws, washers, and nuts in the left output drive flange and secure with four cap screws; rear, right rear, and upper right engine mounts. then align and secure the front propeller shaft to the differential input flange.
  • Page 103 8. Install the transmission level stick mount using a new O-ring; then connect the throttle cable and thread the throttle cable housing into the bracket. DE587 11. Install the muffler and secure to the exhaust pipe with two springs making sure the grafoil seal is in place;...
  • Page 104 15. Install the V-belt cooling fan assembly; then install the V-belt cooling boots to the V-belt housing. DE077C DE076A 16. Connect the V-belt cooling fan connector. DE494A 13. Connect the fuel supply and return hoses and secure with the hose clamps. DE518A 17.
  • Page 105 DE073A DE066A 19. Install the air diverter and tighten the clamps 21. Connect the shift linkage to the transmission shift securely. arm and secure with the E-clip. 20. Secure the engine and main harness grounds to the transmission at the location noted during removal; then connect the speed sensor connector to the speed sensor.

  • Page 106: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (White smoke present) Condition Remedy 1. Glow plugs not heating 1. Check and troubleshoot glow plugs 2. Glow plug heating insufficient 2. Recycle glow plugs Problem: Engine will not start or is hard to start - smoke present (Compression too low) Condition Remedy 1.
  • Page 107 Problem: Gears noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - chipped 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - chipped 3. Replace gears 4. Bearings worn 4. Replace bearings 5.

  • Page 108: Fuel/Lubrication/Cooling

    Cat Service Department. Diesel Fuel Injection System The diesel engine in this Arctic Cat ATV is a “compres- sion ignition” engine. Extremely high pressure in the combustion chamber raises air temperature high enough to cause ignition of the fuel upon injection into the com- bustion chamber.

  • Page 109: Unit Injectors

    2. Locate the fuel solenoid mounted on top of the fuel filter head; then disconnect the spade connector from the solenoid. DE078A Unit Injectors DE647B 3. Remove the banjo-fitting bolts (A) and (B) and remove the fuel solenoid. Account for four crush To service the unit injectors, see Top-Side Components in washers.

  • Page 110: Fuel Tank

    CLEANING AND INSPECTING 1. Remove the fuel level sensor and fuel pick-up screen. Account for a seal. 2. Completely drain all contaminated fuel from the fuel tank; then thoroughly wash the tank out with hot, soapy water. 3. Dry the tank interior with compressed air. ...

  • Page 111: Testing Oil Pump Pressure

    Testing Oil Pump Pressure  NOTE: The engine must be warmed up to the speci- fied temperature for this test (see General Informa- tion). 1. Connect the Tachometer to the engine. 2. Disconnect the oil pressure switch connector; then connect the Oil Pressure Test Kit to the oil pressure switch port.

  • Page 112: Hoses/Thermostat

    5. Remove the cap screws and nuts securing the radia- tor to the frame. Hoses/Thermostat 6. Disconnect the fan wiring from the main wiring har- ness; then remove the radiator/fan assembly and account for the grommets and collars. REMOVING 7. Remove the fan/fan shroud assembly from the radiator. 1.

  • Page 113: Water Pump

     NOTE: The fan wiring must be in the upper-right position. Water Pump 2. Install the radiator (see Radiator in this section).  NOTE: The water pump is a non serviceable compo- nent and must be replaced as an assembly. To replace the water pump, see Engine/Transmission - Left-Side Components.

  • Page 114: Electrical System

    RPM operation, short trips, and high amperage accessory usage are also reasons for battery discharge. Maintenance Charging  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is...

  • Page 115: Switches

    Charging the meter selector to the DC Voltage position.  NOTE: Arctic Cat recommends the use of the CTEK 2. Connect the red tester lead to the red/white wire or Multi US 800 or the CTEK Multi US 3300 for battery the positive connector;...

  • Page 116: Brakelight Switch (Handlebar Control)

    RESISTANCE  NOTE: If the meter shows battery voltage, the main (Switch Connector) wiring harness is good; proceed to test the switch/ component, the connector, and the switch wiring har- 1. Set the meter selector to the OHMS position. ness for resistance. 2.

  • Page 117: Thermistor

    Engine Coolant Glow Plug Controller/ Temperature (ECT) Relay Switch/Thermistor The glow plug controller/relay is a plug-in device located under the seat. The glow plug controller/relay applies 12 The ECT switch/thermistor is a two-function device. One DC volts to the glow plugs in the pre-combustion chambers side is a normally open, temperature activated switch that to aid in cold starting.

  • Page 118: Fan Motor

    2. Select the OHMS position on a suitable tester; then 2. Set the meter selector to the DC Voltage position. connect one tester lead to a suitable ground and the 3. Connect the black tester lead to battery ground. other tester lead to the glow plug center connector. The meter must read less than 1 ohm.

  • Page 119: Ignition Switch

    RESISTANCE 6. Slowly move the ATV forward or backward; the meter must show 0 and 6 DC volts alternately.  NOTE: Perform this test on the upper side of the To replace a speed sensor, use the following procedure. connector. 1.

  • Page 120: Drive Select Switch

    RESISTANCE (LO Beam) RESISTANCE 1. Connect the red tester lead to the white wire; then 1. Set the meter selector to the OHMS position. connect the black tester lead to the gray wire. 2. Connect the red tester lead to the orange wire; then 2.

  • Page 121: Starter/Starter Solenoid

    6. Select the 4WD position on the front drive selector switch; then connect the red tester lead to the white/ orange wire in the main harness. The meter must show battery voltage.  NOTE: The 4WD icon on the LCD should illuminate. ...

  • Page 122: Alternator/Regulator

    2. Connect the red tester lead to the battery terminal;  NOTE: If voltage rises above 15.5 DC volts, the reg- then connect the black tester lead to the starter sole- ulator is faulty or a battery connection is loose or cor- noid cable connection on the starter relay.

  • Page 123: Headlights

    INSTALLING 1. Set the meter selector to the DC Voltage position. 1. Place the alternator/regulator into position on the 2. Connect the red tester lead to one wire; then connect engine; then secure with the existing hardware. Do the black tester lead to the other wire. not tighten at this time.

  • Page 124: Fuel Solenoid

    Fuel Solenoid The fuel solenoid is used in conjunction with the ignition switch to control fuel flow from the lift pump to the unit injectors. This enables the operator to shut off the engine quickly using the emergency stop switch or the ignition switch.

  • Page 125: Drive System/Brake System

    The front drive actuator is located on the left side of the front drive input housing. With the engine stopped and Drive System/Brake the ignition switch in the ON position, a momentary System “whirring” sound can be heard each time the front drive selector switch is shifted.

  • Page 126: Front Differential

    INSTALLING 6. Turn the ignition switch to the ON position and check the operation by shifting the selector switch 1. Lubricate the O-ring on the actuator; then ensure that several times. all mounting surfaces are clean and free of debris. 7.
  • Page 127 9. Support the axle to not allow it to drop or hang. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. 10. Remove the lower shock bolts. Account for the lock nuts;...
  • Page 128 14. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case; then remove the actuator. GC004A 2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for assem- CF650 bling purposes.
  • Page 129 KX219 CD107 Assembling Input Shaft 5. Using a seal removal tool, remove the input shaft seal. Account for a spacer. 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside.
  • Page 130 3. Lubricate the input shaft with High-Performance #2 Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess grease to freely escape. Slight pressure on the boot will be present during assembly. Secure with new clamps.  NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air;...
  • Page 131 KX174 KX178 6. Place the differential with the open side down; then  NOTE: If the cover is difficult to remove, pry on the lift the housing off the spider assembly. Account for cover in more than one recessed location. shim(s) and mark as right-side.
  • Page 132 4. Remove any reusable parts from the gear case hous- ing; then discard the housing and lock collar. Assembling Pinion Gear 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar. CC875 CC882 CC876 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
  • Page 133 Shimming Procedure/Shim Selection Case-Side Shims (Backlash) 0402-405 0.051 0402-406 0.055 0402-407 0.059 0402-408 0.063 0402-409 0.067 Cover-Side Shims (Ring Gear End-Play) GC044 4. Install the pinion gear assembly into the housing. Using the 48 mm Internal Hex Socket, secure the 1402-074 0.051 pinion gear assembly with the existing lock collar.
  • Page 134 GC036A GC036B 3. Install the bearing flange onto the gear case cover 5. Place the Backlash Gauge Tool into the splines of the making sure the alignment/locating pin engages the ring gear and install a dial indicator making sure it con- locating hole in the cover;...
  • Page 135 Assembling Differential Assembly 1. With the pinion gear and new bearings installed, place the selected (backlash) shim on the gear case side of the ring gear with the chamfered side toward the ring gear; then install into gear case/differential housing. GC037A Ring Gear End-Play After correcting backlash, ring gear end-play can be...
  • Page 136 CF266A CC892 7. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket. CF267A 4. Apply a liberal coat of grease to the O-ring; then install it on the assembled cover assembly making sure to seat the O-ring completely down around the CC893...
  • Page 137 INSTALLING DIFFERENTIAL 1. Align the splined input yoke with the front output splines; then place the differential into position on the frame and install the cap screws, washers, and new lock nuts. Tighten to 38 ft-lb. Make sure the rubber boot is properly seated on the input yoke. CD110 Removing/Installing Axle Seal ...

  • Page 138: Drive Axles

    7. Secure the lower shock eyelets with cap screws and 10. Install the wheels and tighten to 45 ft-lb (steel lock nuts. Tighten to 50 ft-lb. wheels) or 80 ft-lb (aluminum wheels). 11. Remove the ATV from the support stand. Drive Axles REMOVING REAR DRIVE AXLE 1.
  • Page 139  NOTE: Keeping the axle level will aid in removal. CAUTION Do not attempt to use a slide hammer or gear case/axle damage will occur. CF636 2. Place the white-striped end of the CV joint into a vise. CF633A REMOVING FRONT DRIVE AXLE ...
  • Page 140 CD027 ATV-1048 7. Install the wheel. Tighten to 40 ft-lb (steel wheels) or 3. Apply 80 grams (2/3 of contents) of grease from the 80 ft-lb (aluminum wheels). pack into the bearing housing. 8. Remove the ATV from the support stand and release ...

  • Page 141: Rear Gear Case

    8. Remove the ATV from the support stand and release the brake lever lock. 9. Check the front differential oil level and add oil as necessary. CF648A AT THIS POINT  For servicing the input shaft, pinion gear, needle bear- ing, ring gear, and axle seal, see Front Differential in this section.

  • Page 142: Hub

    GC058A KX041 3. If clearance is as specified, remove the ring gear and 3. Remove the flange nut securing the hub. thrust button; then place a drop of red Loctite #271 4. Remove the brake caliper. on the threads and tighten to 8 ft-lb (left-hand threads).

  • Page 143: Hydraulic Brake Caliper

    3. Install the hub assembly onto the shaft. 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.
  • Page 144 PR237A PR713A PR238 PR715 5. Remove the caliper holder from the caliper and dis- ! WARNING card the O-ring. Make sure to hold the towel firmly in place or the piston could be ejected from the housing causing injury. 7. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing;...
  • Page 145 PR719C PR715 4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented.  NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR717A 2. Press the piston into the caliper housing using hand pressure only.

  • Page 146: Troubleshooting Drive System

    7. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb. 8. Fill the reservoir; then bleed the brake system (see Periodic Maintenance/Tune-Up). ! WARNING Never use brake fluid from an open container or reuse brake fluid.

  • Page 147: Suspension

    Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. D.

  • Page 148: Front A-Arms

    Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the cotter pin from the nut. Discard the cotter AF618D pin.
  • Page 149 AF616D AF610D 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount; then secure the hose to the A-arm with the routing clamp. 1. Thoroughly clean all A-arm components using a pressure washer. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes.

  • Page 150: Rear A-Arms

    AF618D CD008 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten to 45 ft-lb (steel wheels) install the hub assembly onto the drive axle. or 80 ft-lb (aluminum wheels). 14. Remove the ATV from the support stand. Rear A-Arms REMOVING 1.

  • Page 151: Wheels And Tires

    6. Secure the brake caliper to the knuckle with new “patch-lock” cap screws (right side only). Tighten Use only Arctic Cat approved tires when replacing tires. the caliper to 20 ft-lb. Failure to do so could result in unstable ATV operation.
  • Page 152 ! WARNING Do not mix tire tread patterns. Use the same pattern type on front and rear. Failure to heed warning could cause poor handling qualities of the ATV and could cause excessive drive train damage not covered by warranty. TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0.49 kg/ cm²...

  • Page 153: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber 3. Shock absorber preload too low 3. Adjust shock absorber preload Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1.
  • Page 154 NOTES...
  • Page 155 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-402...

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