Arctic Cat DVX 400 2008 Service Manual
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Arctic Cat DVX 400 2008 Service Manual

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2008 Arctic Cat DVX 400 ATV
model. The manual is designed to aid service personnel in service-oriented applications and may be used as a textbook
for service training.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. A
troubleshooting section is also included in this manual.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. 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. Be sure to fol-
low the directive because it deals with the possibility of severe personal injury or even death. The symbol
! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol
mation worthy of particular attention. The symbol
cific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2007 Arctic Cat Inc.
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
NOTE: identifies supplementary infor-
AT THIS POINT directs the technician to certain and spe-
Back to TOC
September 2007

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  • 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. Be sure to fol- low the directive because it deals with the possibility of severe personal injury or even death.

  • Page 2: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Foreword Click on the red text to go. Section MORE TO GO ON. DVX 400 DVX 400 General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8.

  • Page 3: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Break-In Procedure ..........1-2 Gasoline - Oil - Lubricant ........1-2 Genuine Parts ............1-3 Preparation For Storage.......... 1-3 Preparation After Storage........

  • Page 4: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has General Specifications* reached normal operating temperature. Do not idle the engine for excessively long periods of time.

  • Page 5: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 When using ethanol blended gasoline, it is not neces- sary to add a gasoline antifreeze since ethanol will pre- vent the accumulation of moisture in the fuel system. ! CAUTION Do not use white gas.

  • Page 6: Preparation After Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter hous- Preparation After ing cover and air filter. Start the engine and allow Storage it to idle;...
  • Page 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Cleaner .............. 2-4 Valve/Tappet Clearance ......... 2-6 Tappet Shim Selection Table (Exhaust) ....2-9 Tappet Shim Selection Table (Intake) ....

  • Page 8: Periodic Maintenance Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect C = Clean L = Lubricate Periodic Maintenance CH = Charge D = Drain Chart R = Replace Initial Service Every Every Every 3...

  • Page 9: Lubrication Points

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Lubrication Points Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 4. Using a multimeter, test the battery voltage. The It is advisable to lubricate certain components periodi- meter must read at least 12.5 DC Volts for a fully...

  • Page 10: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If voltage in step 7 is below specifica- tions, charge the battery an additional 1-5 hours; Air Cleaner then retest. 8. Place the battery in the battery compartment; then...
  • Page 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP013 SP119 5. Fill a wash pan larger than the filter with a REMOVING non-flammable cleaning solvent; then dip the filter in the solvent and wash it. 1. Remove the seat.

  • Page 12: Valve/Tappet Clearance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Air Cleaner Assy 2. Filter 3. Holder 4. Stopper 5. Screw 6. Outlet Tube 7. Elbow Fitting 8. Breather Plug 9. Clip 10. Clamp 11. Clamp 12. Flame Trap SP014A 7.
  • Page 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP121 SP124 6. Insert a feeler gauge between the tappet and the NOTE: The valve/tappet clearance specification camshaft. The clearance must be within specifica- is different for intake and exhaust valves. The tions.
  • Page 14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Select a replacement tappet shim that will provide 5. Install the camshaft (see Section 3). the proper clearance. 6. Rotate the crankshaft through two full revolutions to ensure that all excess oil is squeezed from the...
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2152 www.mymowerparts.com Next Back Back to TOC Back to Section TOC...
  • Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2153 www.mymowerparts.com Next Back 2-10 Back to TOC Back to Section TOC...

  • Page 17: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Testing Engine Spark Plug Compression A light brown insulator indicates that the plug is cor- rect. A white or dark insulator indicates that the engine To test engine compression, use the following proce- may need to be serviced or the carburetor may need to dure.

  • Page 18: Gas/Vent Hoses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the three Allen-head cap screws securing the spark arrester to the muffler; then remove the spark arrester. AL611D 2. Slide the rubber boot away and turn the adjuster until the throttle cable has proper free-play of 3-5 mm (1/8-1/5 in.) at the lever.

  • Page 19: Engine/Transmission Oil - Filter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP008A ATV2027 ! WARNING Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM. Engine/Transmission Oil - Filter OIL - FILTER ATV2028 4.

  • Page 20: Adjusting Clutch Lever Cable

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Loosen the lock nut; then turn the adjuster to NOTE: Clean up any excess oil after removing obtain 10-15 mm (0.4-0.6 in.) free-play measured the filter. at point (A).

  • Page 21: Suspension/Shock Absorbers/Bushings

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 F. Knuckles not worn, cracked, or damaged. To replace the headlight bulb, use the following proce- dure. G. Cotter pins not damaged or missing. 1. Turn the bulb counterclockwise; then remove from the reflector housing.

  • Page 22: Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming Switches surface (wall or similar aiming surface). NOTE: There should be an average operating load on the ATV when adjusting the headlight aim.

  • Page 23: Frame/Welds

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Frame/Welds The frame and welds should be checked periodically for damage, bends, cracks, deterioration, broken com- ponents, and missing components. If replacement or repair constitutes removal, see Section 8. Electrical Connections...
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 E. Perform steps B, C, and D on the other FRONT bleeder screw repeating step C until no air bub- bles are observed in the bleeder line. Make sure that the brake lever is firm.
  • Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF739DB SP128 3. If thickness of any brake pad is less than 2.0 mm NOTE: Make sure the detent of the brake pad is (0.078 in.), all brake pads must be replaced.
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MEASURING/REPLACING REAR 5. Using a calipers, measure the thickness of each brake pad. BRAKE PADS 6. If the thickness of any brake pad is less than 2.0 1. Release the parking brake, if applied; then remove mm (0.078 in.), all brake pads must be replaced.

  • Page 27: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Loosen the parking brake cable adjuster (3) and turn the adjuster (4) to achieve a cable length of Burnishing Brake Pads 47-51 mm (1.9-2.0 in.) at (A). Brake pads (both hydraulic and auxiliary) must be bur- nished to achieve full braking effectiveness.

  • Page 28: Drive Chain

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP019 SP061A 2. Count out 21 pins on the chain and measure the ! CAUTION distance between the two points. If this distance exceeds the service limit of 31.94 cm (12.57 in.), After operating the ATV for the initial 5-10 minutes, the chain must be replaced.
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP061B SP061B 4. Locate and remove the master link (chain connec- tor link); then remove the drive chain. 5. Remove the four cap screws securing the driven sprocket to the sprocket hub; then remove the sprocket from the axle.
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP136 SP018A 13. Install a new cotter pin; then install the wheel and tighten the lug nuts to specifications (see Section 10) using the pattern shown. www.mymowerparts.com Back 2-24 Back to TOC...
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 www.mymowerparts.com Table of Contents (DVX 400)........3-3 Back to TOC...
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAMSHAFT AND CYLINDER HEAD Engine/Transmission Cam Lobe Height (min) (intake) 36.020 mm (1.418 in.) (exhaust) 34.900 mm (1.374 in.) Camshaft Journal Oil Clearance (max) 0.15 mm (0.0059 in.) Camshaft Journal Holder Inside 22.012-22.025 mm...
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLUTCH Removing Engine/ Clutch Cable Free Play 10-15 mm (0.394-0.591 in.) Transmission Drive Plate (fiber) Thickness (min) 2.62 mm (0.103 in.) Drive Plate (fiber) Tab (min) 13.2 mm (0.520 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.)
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the engine oil outlet pipe (3) and the inlet pipe (4); then remove the spacer and O-ring from behind the outlet pipe. SP141 11. Disconnect the breather hose (6); then remove the oil return tank (7) and the drain-back hose (8).
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP144 SP147A 16. Disconnect the alternator lead wire couplers (3) 19. Remove the lower radiator bolt (3) and swing the and the neutral switch lead coupler (4). bottom of the radiator forward.

  • Page 36: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP058 ATV2158 22. Work the engine forward to clear the swing-arm; then remove the engine assembly from the left-side of the frame. Left-Side Components NOTE: For efficiency, it is preferable to remove SP060 2.

  • Page 37: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the right-side components are to be NOTE: To aid in installing, it is recommended removed, do not remove the rotor/flywheel. Pro- that the assemblies be kept together and IN ceed to step 7.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the alignment pins (5) and the gasket (6). SP160 7. Remove the primary driven gear assembly (1) and SP156 the washer (2); then remove the collar (3). 3. Hold the rotor/flywheel nut using a 27 mm offset wrench;...
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the top-side components have not been removed, the tensioner and cam chain cannot be removed. 9. Remove the oil pump idler gear (7), the oil pump driven gear (8), and the oil pump drive pin (9);...

  • Page 40: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 17. Remove the Allen-head cap screws securing the neutral switch housing (1); then remove the switch. Account for one O-ring (2) two switch contacts (3 and 4), and two springs behind the switch contacts.
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the valve cover cap screws in a diagonal pattern; then remove the valve cover accounting for two washers (1) and one rubber cushion (2). SP177 SP181A NOTE: Before removing the camshaft journal caps, the piston must be at top-dead-center of the compression stroke.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP186 AT THIS POINT SP183 6. Remove the four cylinder head cap screws in a To service cylinder, see Servicing Top-Side Compo- diagonal pattern noting the locations of the 6 mm nents sub-section.

  • Page 43: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission frame. Complete Removing procedures for Left-Side, Right-Side, and Top-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove...

  • Page 44: Servicing Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents (Servicing Components) NOTE: Critical engine/transmission specifica- tions are located at the beginning of this section. Servicing Top-Side Components ......3-14 Valve Assembly ..........3-14 Piston Assembly ..........3-19 Cylinder/Cylinder Head Assembly .....
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP196A SP200 2. Using a suitable magnet, remove the tappets (3) 4. Remove the valve spring retainer (2) and the valve and the shims (4). spring (3); then remove the valve (4).
  • Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Check the gasket surface of the cylinder head for distortion using a straightedge and feeler gauge. Take clearance readings at several places. If any clearance reading exceeds the service limit specifi- cations, replace the cylinder head with a new one.
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC131D CC142D 3. Push the valve from side to side; then from top to 3. To install a valve guide, use a valve guide installer bottom. and gently drive a valve guide with a retaining clip into the bore from the valve spring side until the 4.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Valve Seat/Guide Servicing Flow 2. Insert an intake valve seat pilot shaft into one of the intake valve guides. Slide the intake valve seat Chart grinding tool onto the pilot shaft; then using light...

  • Page 49: Piston Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Piston Rings 2. Insert each valve into its original valve location. 3. Install the valve springs with the painted end of the 1. Starting with the top ring, slide one end of the ring spring facing away from the cylinder head.

  • Page 50: Cylinder/Cylinder Head Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifica- tions.
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90°...
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV1013A ATV2161 2. The lobe heights must not exceed minimum speci- 5. If clearance is excessive, measure the journals of fications. the camshaft. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting.

  • Page 53: Servicing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install the starter driven gear (1) into the starter clutch; then check that the rotor (2) turns in the Servicing Left-Side direction of the arrow (3) while holding the driven Components gear.

  • Page 54: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring) CC245D NOTE: Prior to inspecting and measuring compo- 3.

  • Page 55: Crank Balancer Driven Gear

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Measure the free length of the springs. If any spring free length is less than 10.3 mm (0.41 in.), replace all four springs. SP211A NOTE: Do not attempt to disassemble the oil pump housing assembly.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP215 ATV2167 2. Remove the oil jet, install a new O-ring, apply 5. To replace a bearing, remove the bearing retaining engine oil, and install. screws; then use the bearing remover to pull the bearing from the crankcase.

  • Page 57: Crankshaft Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Inspect all the oil seals for wear, nicks, or lip dam- age. If any damage is found, replace the seal. 8. Thoroughly clean all crankcase mating surfaces prior to assembly.

  • Page 58: Driveshaft

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. CC223D NOTE: Note the orientation of the four small dogs and the 1st driven gear for assembling purposes.
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC206D SP221 ! CAUTION It is very important to assure the oil feed hole in the bushing and oil supply hole in the driveshaft align. If not aligned, engine damage will result.

  • Page 60: Countershaft

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Install the reverse dog onto the driveshaft making sure the four small dogs are facing toward the 1st driven gear as noted in disassembling. 8. Install the 1st driven washer (right side) onto the shoulder of the splined shaft;...

  • Page 61: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC199D CC201D 6. Remove the remaining 5th drive washer from the 5. Install the 2nd drive gear and washer onto the countershaft. countershaft. Assembling 1. Install the first 5th drive washer onto the counter- shaft.

  • Page 62: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP223 SP226 2. Install the crank balancer shaft. 3. Simultaneously, install the driveshaft and counter- Joining Crankcase shaft assemblies making sure the washer is on the Halves countershaft. 4. Making sure the circlip is in position, install the reverse idler shaft;...

  • Page 63: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Right-Side Components NOTE: Critical torque specifications are located in Section 10. A. Primary Drive Gear B. Crank Balancer Gear C. Cam Chain SP230 4. From the right side, install the eight case half cap NOTE: It will be necessary to install the starter screws (three inside the case);...
  • Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP233 SP235A 6. Install the crank balancer driven gear (5) aligning the timing marks (6); then holding the generator rotor with a 27 mm offset wrench, tighten the crank balancer driven gear nut to specifications.
  • Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2170A SP241 11. Install the oil pump idler gear and secure with a circlip. F. Oil Pipe G. Clutch NOTE: Steps 1-11 of the preceding sub-sections must precede this procedure.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 16. Install the drive and driven plates one by one into the clutch hub sleeve in the prescribed order. NOTE: Be sure to install the drive plate with the inside diameter of 122.5 mm (4.82 in.) first. Two dif- ferent types of drive plates are used.

  • Page 67: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP249 SP254 SP250 SP255 Installing Left-Side Installing Top-Side Components Components NOTE: Critical torque specifications are located NOTE: Critical torque specifications are located in Section 10. in Section 10. A. Neutral Switch A.
  • Page 68 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2173 SP256 ATV2174 SP257 5. Apply engine oil to the sliding surface of the pis- NOTE: The first (1) and second (2) rings differ in ton and the big end of the connecting rod; then shape.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder Head D. Camshafts E. Valve Cover F. Cam Chain Tensioner NOTE: Steps 1-7 of the preceding sub-section must precede this procedure. 8. Install the cylinder head on the cylinder.
  • Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP263 12. Apply moybdenum oil solution to the camshaft journals, camshaft lobes, and the camshaft journal holders; then place each camshaft into the correct position. ATV2177 16. Install the alignment pins (1) and cam chain guide;...

  • Page 71: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP267 SP270 19. Install a new gasket and the cam chain tensioner assembly into the cylinder making sure the UP Installing stamp is directed towards the cylinder head. Engine/Transmission 20. Tighten the cam chain tensioner Allen-head cap screws to specifications;...
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Tighten the engine mounting fasteners to the spec- 6. Install the engine coolant hose; then install the ifications. spacer (1) with O-ring to the engine oil outlet pipe and tighten the cap screws (2) securely.
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Fill the oil tank (see Section 2). 14. Fill the cooling system with the appropriate mix of Arctic Cat anti-freeze and water (see Section 2). 15. Connect all remaining electrical connections; then install the battery making sure to connect the posi- tive battery cable first and the negative cable last.
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-2 Cleaning and Inspecting Carburetor......4-5 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle)........... 4-6 Gas Tank ..............

  • Page 75: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor Carburetor Specifications ! WARNING ITEM Whenever any maintenance or inspection is per- Type Mikuni BSR36 formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- Main Jet ing, open flames, etc., in the area.
  • Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Disconnect the throttle cable from the actuator 3. Remove the two screws securing the primer hous- arm; then loosen the outer jam nut (6) securing the ing cover. Account for the primer diaphragm throttle cable to the carburetor body and route the assembly (11) and spring.
  • Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT Prior to assembling, the carburetor components should be cleaned and inspected (see Cleaning and Inspecting Carburetor sub-section). ASSEMBLING 1. Screw the idle adjustment screw into the carbure- tor making sure the washer and spring are properly positioned.

  • Page 78: Cleaning And Inspecting Carburetor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Position the spring and primer diaphragm assem- 5. Place the throttle actuator cover into position on bly (lip toward the carburetor) onto the carburetor; the carburetor making sure the O-ring is properly then secure the assembly with the primer housing positioned;...

  • Page 79: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Inspect the carburetor mounting flange for damage 5. Remove the cap screws securing the gas tank to and tightness. the frame; then remove the air-intake snorkel (4). Throttle Cable Free-Play To check/adjust throttle cable free-play, see Section 2.

  • Page 80: Fuel Valve

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel Valve Oil Flow Chart REMOVING/INSPECTING ! WARNING Drain the gas tank prior to this procedure. 1. Remove the hose from the fuel valve by releasing the spring clamp; then remove the vacuum hose.

  • Page 81: Testing Oil Pump Pressure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING/DISASSEMBLING 3. Start the engine and run at the specified RPM. 4. The oil pressure gauge must read 0.2 kg- (2.8 1. Remove the oil pump from the engine (see Section cm²...

  • Page 82: Liquid Cooling System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the cap screws securing the tank to the 4. Install the radiator (see Radiator/Fan in this sec- frame; then remove the overflow hose and remove tion) and fill the cooling system.

  • Page 83: Radiator/Fan

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install the upper and lower coolant hoses; then secure with hose clamps. Radiator/Fan 4. Install the front bumper (see Section 8). 5. Fill the cooling system with 1.2 L (1.3 U.S. qt) of antifreeze.

  • Page 84: Water Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: All coolant hoses and clamps should be replaced every four years. INSTALLING 1. Place the thermostat into the thermostat housing; then secure the thermostat housing to the cylinder head with the two cap screws.
  • Page 85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP299 CC772 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all oil-pump components in cleaning sol- vent.
  • Page 86 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP305 SP310 4. Install the washer (1), drive pin (2), and driven 2. Install the clutch cover and tighten the cap screws gear (3); then install the circlip (4). Make sure the securely;...

  • Page 87: Engine Coolant Temperature Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine Coolant Cooling Fan Temperature Switch Thermo-Switch REMOVING REMOVING 1. Drain the coolant in the radiator to a point below 1. Drain the coolant in the radiator to a point below the upper temperature switch.
  • Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Specifications ............5-2 Battery..............5-2 Testing Electrical Components........ 5-2 Brakelight Switch............. 5-2 Coolant Temperature and Cooling Fan Switches ..5-3 Fan Motor ..............5-3 Fuse Holder.............

  • Page 89: Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications Brakelight Switch FRONT BRAKE IGNITION Ignition Timing 10° BTDC @ 1500 RPM NOTE: For ease of access to the electrical con- Spark Plug Type NGK CR7E nectors, removing the seat and body is recom- Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)

  • Page 90: Coolant Temperature And Cooling Fan Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Coolant Temperature Fan Motor and Cooling Fan Switches NOTE: The ignition switch must be in the ON position. 1. Connect the meter leads (selector in the OHMS VOLTAGE (Main Harness position) to the switch contacts.

  • Page 91: Fuse

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Connect the black tester lead to ground. 2. Using the multimeter with the peak voltage adapter, connect the red tester lead (+) to the 4. Using the red tester lead, contact the battery side black/white lead wire (or to ground) and the black of the fuse holder connector terminal.

  • Page 92: Indicator Lights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Secondary Winding 2. Disconnect the four-wire connector from the main wiring harness. 1. Connect the red tester lead to the high tension lead NOTE: For these tests, a 12-volt power supply (plug cap removed);...

  • Page 93: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Ignition Switch Handlebar Control Switches The connector is the three-wire one in front of the steering post. To access the connector, the body and The connector is the yellow one in front of the steering seat must be removed (see Section 8).

  • Page 94: Neutral Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Emergency Stop) 6. Rotate the reverse selector knob clockwise and depress the gear shifter pedal to engage reverse gear; then connect the red meter lead to the red 1. Set the meter selector to the OHMS position.

  • Page 95: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Charging Coil) NOTE: If voltage is lower than specified, test Charging Coil - No Load. ! CAUTION VOLTAGE (Charging Coil - No Load) Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.
  • Page 96 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING/DISASSEMBLING 2. Inspect all threaded areas for damage or stripped threads. 1. Disconnect the battery. 3. Inspect the brush holder assembly and brushes for damage or wear. Using a caliper, measure the ! CAUTION length of the brushes.
  • Page 97 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Using the red tester lead, probe the commutator 6. Apply a small amount of grease to the left-side end of the armature. The meter indicator should cover bushing. not change. If the indicator shows resistance, 7.

  • Page 98: Starter Relay

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Prior to replacing the CDI unit to assure the CDI unit is defective, it is advisable to perform Starter Relay a CDI peak voltage test (see Ignition Coil in this...

  • Page 99: Taillight - Brakelight

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The center bulb is the low beam one. NOTE: If the meter shows no voltage, inspect fuses, wiring harness, connectors, and switches. If 1. Turn the ignition switch to the lights position; then the meter shows battery voltage, replace the bulb.

  • Page 100: Ignition Timing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. With the throttle in the full-open position, the 2. Connect the three-pin connector on the TPS har- meter must read 3.7-4.9K ohms. ness to the main wiring harness. 5. With the red tester lead connected to the yel- NOTE: No adjustments can be made to the TPS.
  • Page 101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Rear Drive Assembly Schematics ......6-2 www.mymowerparts.com Rear Drive Axle ............6-2 Back to TOC...
  • Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RIGHT REAR WHEEL ASSEMBLY 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. NOTE: Critical torque specifications are located in Section 10.
  • Page 103 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP061B SP317 4. Remove the rear wheel hubs; then remove the NOTE: Do not attempt to remove the brake disc left-side axle nuts (1). Account for two concave flange. The axle and brake flange are an assembly.
  • Page 104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the axle bearings by rotating them by hand. If any roughness, binding, or excessive looseness is found, replace the axle bearings. NOTE: If the axle bearings are replaced, replace the dust seals with new ones.
  • Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Apply Three Bond Sealant to the left and right L x Ts ends of the sprocket hub; then install the hub on L + Ls the axle. T: Torque wrench reading to be calculated...
  • Page 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension Assembly Schematics ......7-2 Front Shock Absorbers..........7-2 Rear Shock Absorber ..........7-4 Swing Arm............... 7-6 Front A-Arms ............7-11 Wheels and Tires ..........7-16 www.mymowerparts.com...

  • Page 107: Suspension Assembly Schematics

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SWING ARM Suspension Assembly Schematics 1. Swing Arm Assy 2. Bearing 3. Bushing 4. Seal 5. Spacer 6. Dust Cover FRONT SUSPENSION 7. Washer 8. Pivot Shaft 1. Shock Absorber 9.
  • Page 108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING ADJUSTING SPRING PRELOAD The preload is adjustable by changing the spring set NOTE: Whenever a part is worn excessively, length. Using the following procedure, adjust the cracked, or damaged in any way, replacement is spring.

  • Page 109: Rear Shock Absorber

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Rebound ! WARNING 1. Turn the lower damping force adjuster screw (1) Make sure the ATV is solidly supported on the sup- fully clockwise. port stand to avoid injury. 2. Remove the rear arm guard (1); then remove the swing-arm guard (2).
  • Page 110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 To release gas pressure, remove the valve cap; then using a screwdriver, depress the valve releasing the gas. SP328 SP331 ! WARNING Direct the valve stem away from your body. Always wear protective eyewear when releasing high-pres- sure gas.

  • Page 111: Swing Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP336 SP334 2. Turn the adjuster 1 1/2 turns counterclockwise for SPRING SET LENGTH the “standard” setting. MAXIMUM MINIMUM STANDARD Compression (SOFTEST) (STIFFEST) 233 mm (9.17 in.) 238 mm (9.37 in.) 228.5 mm (9.00 in.)
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP338 SP341 3. Remove the rear arm (3); then remove the front arm (4). SP342 7. Remove the swing-arm pivot nut; then remove the swing-arm pivot shaft and remove the swing arm.
  • Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the dust covers (1), washers (2), and spac- ers (3) from the swing arm; then remove the spac- ers from the front arm and rear arm. SP348 SP345 ATV2192 3.
  • Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP350 SP353 NOTE: Removed bushings must be replaced with new ones. 5. To inspect front and rear arm bearings, insert the spacer into the bearing; then check for excessive play by moving the bearing up and down. If exces- sive play is noted, the bearing must be replaced.
  • Page 115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2194 SP358A 3. Apply multipurpose grease to the lip of the dust ASSEMBLING AND INSTALLING covers; then install the dust covers (1), washers (2), and spacers (3) to the swing arm.

  • Page 116: Front A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP361 SP365 8. Install the rear arm guard and the swing-arm NOTE: The stamped mark of the dust seals must guard. be directed toward the outside of the assemblies. 5. Install the swing arm and pivot shaft; then install...
  • Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP367 CD877A 5. Remove the hub assembly; then remove the disc cover (2). SP371 8. Remove the shock absorber lower mounting cap SP368 6. Remove the cotter pin and slotted nut securing the screw (4);...
  • Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Using a ball joint remover (8), remove the ball joint from the knuckle (7). SP377 SP374 CLEANING AND INSPECTING 1. Clean the knuckle in parts-cleaning solvent; then dry with compressed air. If any damage or exces- sive wear is detected, the knuckle must be replaced.
  • Page 119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP380 SP383 5. Check the bearings for excessive wear and replace them if worn. SP384 2. Install the bearings in the upper arm pivot to a depth of 12 mm (0.47 in.) with a bearing installer and suitable spacer.
  • Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Coat the spacers (2) and the lips of the dust seals (3) with multipurpose grease; then install them in the upper pivot. SP390 6. Install the arms to the frame with the pivot cap screws;...

  • Page 121: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. SP393 The ATV is equipped with low-pressure tubeless tires 9.
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Make sure each wheel is installed on its NOTE: If repair is needed, follow the instructions proper hub as noted in removing (the “rotation found on the tire repair kit or remove the wheel arrow”...
  • Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering Post/Tie Rods ........... 8-2 Measuring/Adjusting Toe-In/Toe-Out ....... 8-7 Body ................ 8-7 www.mymowerparts.com Back to TOC...
  • Page 124 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering Post/Tie Rods NOTE: Critical torque specifications are located in Section 10. 1. Steering Post 2. Dust Seal 3. Steering Post Holder 4. Cap Screw SP395 5. O-Ring 3. Disconnect the parking brake cable (3) and clutch 6.
  • Page 125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP398 SP401 6. Drain the engine oil from the oil tank; then drain the coolant from the radiator. 7. Remove the radiator assembly (1) (see Section 4). SP402 SP399 8. Remove the two fasteners; then remove the oil hose protector.
  • Page 126 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Remove the steering post (9); then remove the dust seals (10), and the steering post holder half (11). SP405 11. Remove the cotter pin, steering post nut (5), washer (6), and dust seal (7) accounting for the O-ring (8);...
  • Page 127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Inspect the handlebar grips for damage or wear. INSTALLING 1. Apply multipurpose grease to the steering post and dust seal; then install the dust seal (1) to the steer- ing post.
  • Page 128 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Adjust the handlebar in the holders to align the punch mark (B) with the mating surface of the handlebar holders. Tighten first the forward cap screws (4) to specifications; then tighten the rear- ward cap screws (5) to specifications.
  • Page 129 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP421 ATV2204 13. Install the throttle lever case to the handlebar 3. Measure the distance (A) and (B) between the aligning the housing mating surface with the front wheels; then subtract distance (B) from (A).
  • Page 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP107 SP100 5. Remove the screw securing the front lip of the NOTE: Always remove the negative battery cable body to the headlight housing. first; then the positive. Install the positive cable cable first;...
  • Page 131 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP105 SP100 8. Lift the body clear of all brackets and studs; then 3. Install the front lip screw into the headlight hous- rotate clockwise and work handlebar through the ing;...
  • Page 132 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP106 SP107 7. Install the starter relay; then install the seat making sure it is locked securely front and rear. www.mymowerparts.com Back 8-10 Back to TOC Back to Section TOC...

  • Page 133: Controls/Indicators

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Front Brake Lever/Master Cylinder Assembly ..9-2 Rear Brake Pedal/Master Cylinder Assembly ..9-3 Throttle Control ............9-5 Reverse Selector/Lock ..........9-6 www.mymowerparts.com...

  • Page 134: Front Brake Lever/Master Cylinder Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Brake Lever/ Master Cylinder Assembly NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Place a shop towel under the brake hose union bolt SP424 4.

  • Page 135: Rear Brake Pedal/Master Cylinder Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the brake hose for cracks and deterioration and the condition of the fittings (threaded and compression). 5. Inspect the brakelight switch for corrosion, cracks, missing or broken mounting tabs, or broken and frayed wiring.
  • Page 136 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP429 SP433 ! CAUTION INSPECTING Brake fluid is highly corrosive. Do not spill brake 1. Inspect the master cylinder bore for any scratches fluid on any surface of the ATV.

  • Page 137: Throttle Control

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP435 AF677D 5. Install the reservoir tank hose; then fill the master 4. Remove the actuator arm and account for a bush- cylinder reservoir with DOT 4 brake fluid and ing.

  • Page 138: Reverse Selector/Lock

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ADJUSTING To adjust the throttle cable, see Section 2. Reverse Selector/Lock REMOVING 1. Remove the reverse selector knob mounting screw; then remove the cap screw securing the lower cable housing to the reverse cable bracket.

  • Page 139: Aids For Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications ..........10-2 Torque Conversions ..........10-3 www.mymowerparts.com Tightening Torque (General Bolts) ......10-3 10-1 Back to TOC...

  • Page 140: Torque Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHASSIS COMPONENTS Torque Specifications Torque Part Part Bolted To kg-m ft-lb Footrest Mounting Cap Frame DRIVE TRAIN COMPONENTS Screw * Torque SUSPENSION COMPONENTS (Front) Part Part Bolted To kg-m ft-lb...

  • Page 141: Tightening Torque

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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...
  • Page 142 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 11 - TROUBLESHOOTING TABLE OF CONTENTS Engine ..............11-2 Fuel System ............11-6 Electrical..............11-7 Steering/Suspension ..........11-9 Brakes ..............11-10 www.mymowerparts.com 11-1 Back to TOC...

  • Page 143: Engine

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine 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 144 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine noisy (Noise seems to come from timing chain) Condition Remedy 1. Chain stretched 1. Replace chain 2. Sprockets worn 2. Replace sprockets 3. Tension adjuster malfunctioning 3. Repair - replace adjuster...
  • Page 145 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Transmission will not shift back Condition Remedy 1. Reverse shift cam broken 1. Replace cam 2. Shift shafts rubbing - sticking 2. Repair shafts 3. Gearshift forks distorted - worn 3.
  • Page 146 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 147: Fuel System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 148: Electrical

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 149 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 150: Steering/Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 151: Brakes

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1. Replace bushings Problem: Suspension noisy Condition Remedy 1. Cap screws (suspension system) loose 1. Tighten cap screws 2. A-arm-related bushings worn 2.

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