Arctic Cat 400TRV 2011 Service Manual
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Arctic Cat 400TRV 2011 Service Manual

Arctic Cat 400TRV 2011 Service Manual

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For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 400 TRV. The complete manual is designed to aid service personnel in service-oriented applications.
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.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete 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 follow the directive because it deals with the possibility of severe personal injury or even death. A
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  NOTE: identifies supplementary
AT THIS POINT directs the technician to certain
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs 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.
© 2010 Arctic Cat Inc.
October 2010
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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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.
  • Page 2 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Click on the blue text to go. Service TABLE OF CONTENTS Manual Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, click the Manual Table of Contents button at the bottom of each page.
  • Page 3 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-3 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........1-3 Genuine Parts ............
  • Page 4 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 General Specifications SUSPENSION COMPONENTS (Rear) Torque Part Part Bolted To ft-lb N-m Shock Absorber (Upper) Frame CHASSIS Shock Absorber (Lower) Lower A-Arm Brake Type Hydraulic w/Brake Lever Lock A-Arm Frame and Auxiliary Brake...
  • Page 5 21.8 55.8 89.8 123.8 CAUTION 23.1 57.1 91.1 125.1 24.5 58.5 92.5 126.5 Do not use white gas. Only Arctic Cat approved gaso- 25.8 59.8 93.8 127.8 line additives should be used. 27.2 61.2 95.2 129.2 RECOMMENDED ENGINE/ 28.6 62.6 96.6...
  • Page 6 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE Preparation For Storage LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 CAUTION hypoid. This lubricant meets all of the lubrication...
  • Page 7 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Clean the ATV thoroughly. CAUTION 2. Clean the engine. Remove the cloth from the exhaust Connect the positive battery cable first; then the nega- system. tive. 6. Check the entire brake systems (fluid level, pads, 3.
  • Page 8 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Air Filter..............2-3 Valve/Tappet Clearance .......... 2-4 Testing Engine Compression ........2-4 Spark Plug............... 2-5 Muffler/Spark Arrester ..........
  • Page 9 * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval and strainer inspection can be increased to every 1,000 miles or every year.
  • Page 10 This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV.  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.
  • Page 11 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Valve Adjuster Procedure 2. Replace any drain that is cracked or shows any signs of hardening or deterioration.  NOTE: The seat, storage compartment cover CAUTION assembly, compartment box, air filter/filter housing,...

  • Page 12: Muffler/Spark Arrester

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: The engine should be warm (operating tem- CAUTION perature) and the battery full charged for an accurate compression test. Throttle must be in the wide-open Before removing a spark plug, be sure to clean the area throttle (WOT) position.
  • Page 13 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Install the spark arrester assembly with gasket; then 4. Remove the oil filter plug from the filter mounting secure with the three cap screws. Tighten to 48 in.-lb. boss (located on the front side of the transmission case) and allow the filter to drain completely.
  • Page 14 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 STRAINER 6. Install the belly panel. 1. Remove the belly panel. Front Differential/Rear 2. Remove the cap screws securing the oil strainer cap; then remove the cap. Drive Lubricant When changing the lubricant, use approved SAE 80W-90 hypoid gear lube.
  • Page 15 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Connect the new bulb assembly to the wiring harness connector; then insert into the headlight housing and rotate fully clockwise. To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing.
  • Page 16 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Shift Lever CHECKING ADJUSTMENT ATV-0070C  NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. 2. Measure the distance from the floor to the mid-point of each headlight.
  • Page 17 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Install the left-side engine cover and seat making 2. Compress the brake lever/pedal several times to sure the seat locks securely in place. check for a firm brake. If the brake is not firm, the system must be bled.
  • Page 18 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSPECTING HOSES A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid. Carefully inspect the hydraulic brake hoses for cracks or B. Install and secure the cover; then slowly compress other damage.
  • Page 19 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR377B CD078 5. Install the wheel. Tighten to 40 ft-lb.  NOTE: Note the location of the main engine ground wire for installing purposes. 6. Burnish the brake pads (see Burnishing Brake Pads in this section).
  • Page 20 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a washer and nut (coated with red Loctite #271). Tighten the nut to 147 ft-lb.
  • Page 21 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Troubleshooting ............3-3 Table of Contents (400 TRV) ........3-6 www.mymowerparts.com Manual Table of Contents...
  • Page 22 0.35 mm the engine/transmission does not have to be removed (wobble method) from the frame. Valve Guide Inside Diameter 5.000-5.012 mm  NOTE: Arctic Cat recommends the use of new gas- Valve Stem Outside Diameter (intake) 4.975-4.990 mm (exhaust) 4.955-4.970 mm...
  • Page 23 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Repair - replace guides 3.
  • Page 24 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - rubbing 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - rubbing 3.
  • Page 25 For Discount Arctic Cat 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 incorrect 3. Re-time valve gear 4. Piston ring(s) - cylinder worn 4.
  • Page 26 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the heat shield; then remove the gas tank (see Section 4). Table of Contents 3. Remove the oil fittings from the engine and (400 TRV) account for two O-rings; then disconnect the oil temperature connector and cooling fan connector.
  • Page 27 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring.
  • Page 28 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Remove the front and rear V-belt cooling boots from the V-belt housing. Top-Side Components 9. Remove the cap screws from the front and rear output flanges; then remove the front and rear engine mounting through-bolts.
  • Page 29 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the cylinder head cover cap screws. Note the rubber washers on the four top-side cap screws; remove the cover. Note the orientation of the cylinder head plug and remove it. Note the location of the two alignment pins.
  • Page 30 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1131 CD211 7. Noting the timing marks for installing purposes, 10. Remove the cylinder head from the cylinder, drop the sprocket off the camshaft. While holding remove the gasket, and account for two alignment the cam chain, slide the sprocket and camshaft out pins.
  • Page 31 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 12. Remove the two nuts securing the right side of the NOTE: It is advisable to remove the opposite-side cylinder to the right-side crankcase half. circlip prior to using the puller.
  • Page 32 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Removing Valves Servicing Top-Side NOTE: Keep all valves and valve components as Components a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation.
  • Page 33 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indi- cator. ATV1082A 3. Rotate the valve in the V blocks.
  • Page 34 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing.
  • Page 35 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement exceeds specifications, the piston pin must be replaced.
  • Page 36 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC397D MD1343A 2. Measure the corresponding piston diameter at a CAUTION point 15 mm (0.6 in.) above the piston skirt at a Incorrect installation of the piston rings will result in right angle to the piston-pin bore.
  • Page 37 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CAUTION Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to the sealing surface may result. CC996 Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion CC997 chamber.
  • Page 38 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not avail- able, use a lightweight petroleum-based oil. Thor- oughly clean cylinder after honing using soap and hot water.
  • Page 39 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1261 CF061A 5. Match the width of the plasti-gauge with the chart NOTE: With the weight extended, the unloader found on the plasti-gauge packaging to determine pin should be flat-side out; with the weight...
  • Page 40 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: The two cylinder-to-crankcase nuts will be tightened in step 9. MD1213 2. Place the two alignment pins into position. Place a new cylinder gasket into position; then place a pis-...
  • Page 41 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1347 MD1192 9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to 28 ft-lb. Tighten the two lower cylinder head nuts (from step 8) to 20 ft-lb and the cylinder-to-crankcase nuts (from step 4) to 8 ft-lb.
  • Page 42 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole. MD1359 14. Place the C-ring into position in its groove in the cylinder head.
  • Page 43 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1137 MD1254 19. Rotate the crankshaft until the first cap screw 24. Install the cap screw and spring into the end of the (from step 17) securing the sprocket to the cam- cam chain tensioner.
  • Page 44 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 29. Adjust valve/tappet clearance (see Section 2). 30. Place the two tappet covers with O-rings into posi- tion; then install and tighten the cap screws to 8 ft-lb. MD1186 3. Using an appropriate side case puller and the 6 mm adapter, remove the left-side cover w/stator assembly.
  • Page 45 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1194 MD1369 5. Install the crankshaft protector. MD1370 7. Remove the starter idler gear (No. 1) and starter MD1365 idler gear (No. 2). 6. Using Magneto Rotor Remover Set, break the rotor/flywheel assembly loose from the crankshaft.
  • Page 46 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 11. Remove two starter motor cap screws. MD1122 2. Install the starter motor and tighten the two cap screws to 8 ft-lb.
  • Page 47 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the pivot shaft.
  • Page 48 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1033 MD1118 4. Remove the movable drive face and spacer. 6. Remove the fixed drive face. Account for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assem- MD1035 bly;...
  • Page 49 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 12. Remove the gear position switch. Account for a spacer. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the posi- tions of the different-lengthed cap screws for KC326A 13.
  • Page 50 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1016 MD1019 15. Remove the cam chain. NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 19. Remove oil pump driven gear. Account for the drive pin and thrust washer.
  • Page 51 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSPECTING CENTRIFUGAL 21. Remove the four cap screws securing the oil strainer cap; then remove the Phillips-head screws CLUTCH HOUSING securing the oil strainer. Account for the O-ring. 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear.
  • Page 52 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC332A MD1208 3. Place two alignment pins and the oil pump into INSPECTING OIL PUMP position on the crankcase and secure with the Phil- lips-head screws coated with blue Loctite #243.
  • Page 53 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. MD1019 5. Install the cam chain. NOTE: Keep tension on the cam chain to avoid MD1286 damaging the crankcase boss.
  • Page 54 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1115 MD1068 11. Tighten the clutch cover housing cap screws to 8 ft-lb. KC134 14. Slide the fixed drive face assembly onto the front shaft. MD1117 12. Install the air intake plate. Apply red Loctite #271 15.
  • Page 55 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC127 KC142A 17. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft Center Crankcase protrude through the cover plate, secure with the nut and tighten to 147 ft-lb.
  • Page 56 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1012 FI639A 2. Using Crankcase Separator/Crankshaft Remover 1. Remove the secondary driven shaft assembly (A) and tapping lightly with a rubber mallet, separate noting the location of the front and rear bearing the crankcase halves.
  • Page 57 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. Remove the countershaft assembly (E) along with the shift fork assembly. FI641A 3. Remove the driveshaft (C); then pull the shift fork locating shaft (D) out of the crankcase locating...
  • Page 58 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Remove the secondary drive gear/secondary NOTE: Continue to remove, measure, and install driven gear retaining nut. From inside the crank- until backlash measurement is within tolerance. case using a rubber mallet, drive out the output Note the following chart.
  • Page 59 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ATV-0104 CC290D 2. Maximum diameter must not exceed specifica- Correcting Tooth Contact tions. Measuring Connecting Rod NOTE: If tooth contact pattern is comparable to (Small End Deflection) the correct pattern illustration, no correction is necessary.
  • Page 60 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction.
  • Page 61 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Remove the low driven gear washer; then remove 5. Remove the circlip securing the high driven gear; the low driven gear along with the bearing and then remove a washer, the high driven gear along bushing.
  • Page 62 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Place the reverse driven bushing (13) onto the shaft; then install the bearing (14), gear (15), and splined washer (16). Secure with a snap-ring. FI670 2. Install the high/low shift dog (6) on the counter- shaft and secure with snap-ring (7);...
  • Page 63 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: The countershaft assembly is now ready to be installed. Assembling Crankcase Half NOTE: For ease of assembly, install components on the right-side crankcase half. NOTE: If the output driveshaft was removed, MD1333 make sure that the proper shim is installed.
  • Page 64 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. FI658 6.
  • Page 65 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 FI641A FI661A Joining Crankcase Halves 1. Verify that the two alignment pins are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces.
  • Page 66 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Installing Engine/Transmission 1. From the right side, place the engine/transmission into the frame tilting the top-side forward to clear the frame member. MD1008 4. From the left side, install the remaining crankcase cap screws;...
  • Page 67 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal. Tighten the cap screws evenly to 20 ft-lb and install the muffler retainer springs.
  • Page 68 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC245A KC248 8. Install the air filter housing onto the frame; then 10. Connect the oil temperature connector and cooling connect the inlet air duct, air silencer duct, and fan connector; then using new O-rings, install the...
  • Page 69 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 11. If the brake pedal was removed during disassem- bling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. Tighten to 25 ft-lb.
  • Page 70 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Carburetor Specifications ........4-2 Carburetor ............... 4-2 Electric Choke ............4-7 Throttle Cable Free-Play ......... 4-7 Engine RPM (Idle)........... 4-8 Gas Tank ..............4-8 Oil Filter/Oil Pump ...........
  • Page 71 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Remove the screw securing the throttle actuator cover to the carburetor; then remove the cover. Fuel/Lubrication/Cooling  NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.
  • Page 72 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DISASSEMBLING 3. Remove the three screws securing the pump housing. Account for the diaphragm assembly, spring, and U-ring (in the housing). CC748 1. Cover 12. Electric Choke 23. Spring 4. Remove the Phillips-head screws securing the float 2.
  • Page 73 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC752 CC758 6. Lift the float assembly from the carburetor. Account 10. Unscrew and remove the idle adjust screw. Account for the float valve. for the spring and washer. CLEANING AND INSPECTING ...
  • Page 74 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 12. Inspect the carburetor mounting flange for damage and tightness. ASSEMBLING 1. Thread the idle adjust screw into the carburetor mak- ing sure the washer and spring are properly posi- tioned.
  • Page 75 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC748 CC740A 3. Place the throttle cable into position and secure by CAUTION tightening the outer jam nut. It is important to press down on the pump housing until it contacts the carburetor to make sure the diaphragm lip is properly seated in the groove in the carburetor.
  • Page 76 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Position the carburetor in the air cleaner boot and intake pipe assembly; then secure with the clamps. 7. Connect the hose from the carburetor to the gas tank. 8. Install the air filter housing; then install the seat.
  • Page 77 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.
  • Page 78 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Remove the oil cooler from the frame. Testing Oil Pump INSTALLING Pressure 1. Place the cooler into position in the frame. 2. Secure the cooler to the frame with the cap screws and grommets.
  • Page 79 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 REMOVING 1. Remove the seat; then remove the three clamps securing the gas hoses and vacuum hose and discon- nect the hoses. 2. Remove the two machine screws and flange nuts securing the fuel pump to the electrical tray;...
  • Page 80 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Electrical Connections..........5-2 Specifications ............5-2 Battery..............5-2 RPM Limiter............. 5-3 Testing Electrical Components ........ 5-3 Accessory Receptacle/Connector ......5-3 Brakelight Switch (Auxiliary)........
  • Page 81 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Electrical System Battery This section has been organized into sub-sections which After being in service, batteries require regular cleaning show procedures for the complete servicing of the Arctic and recharging in order to deliver peak performance and Cat ATV electrical system.
  • Page 82 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 B. When using a constant-current battery charger,  NOTE: Arctic Cat highly recommends all ATV batter- use the following Battery Charging Chart. ies be connected to a maintenance charger during storage or any extended period of non-use. This...
  • Page 83 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. The meter must show battery voltage.  NOTE: If the meter shows no battery voltage, trou- bleshoot the battery, fuse, receptacle, connector, or the main wiring harness. Brakelight Switch (Auxiliary) The switch connector is the two-prong connector on the brake switch lead above the gas tank on the right side.
  • Page 84 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 RESISTANCE (Switch Connector)  NOTE: The brake lever must be compressed for this test. Also, the ignition switch must be in the OFF position. 1. Set the meter selector to the OHMS position.
  • Page 85 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. 5. The meter must show battery voltage from one side of the connector terminal ends.
  • Page 86 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Primary Winding 3. Crank the engine over using the electric starter. 1. Connect the red tester lead to either terminal; then 4. The meter reading must be within specification. connect the black tester lead to the other terminal.
  • Page 87 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: If the meter shows no battery voltage, trou- bleshoot the battery or the main wiring harness. RESISTANCE  NOTE: Perform this test on the switch using the fol- lowing procedure.
  • Page 88 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 RESISTANCE (HI Beam)  NOTE: If the meter shows more than 1 ohm of resis- tance, troubleshoot or replace the switch/component, 1. Set the meter selector to the OHMS position. the connector, or the switch wiring harness.
  • Page 89 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Connect the red tester lead to the white wire on the 9. Connect the tester lead to the white/green wire in harness side of the connector. the supply harness. The meter must show 0 DC volts.
  • Page 90 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. The meter reading must be within specification. 3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts RESISTANCE (Trigger Coil) and a “click” should be heard from the relay.
  • Page 91 For Discount Arctic Cat 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 a CDI peak voltage test (see Ignition Coil in this section) and/or perform a continuity test of the wiring harness from the CDI connector to the CDI unit.
  • Page 92 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: If battery voltage is not shown in any test,  NOTE: Make sure the brake lever (hand) and brake inspect the LIGHTS fuse, battery, main wiring har- pedal (auxiliary) are properly adjusted for this proce- ness, connectors, or the left handlebar switch.
  • Page 93 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Charge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter relay defective 3. Replace relay 4. Emergency stop - ignition switch off 4.
  • Page 94 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator/Differential Lock...... 6-2 Front Differential ............6-3 Drive Axles ............6-16 Rear Gear Case ............ 6-19 Hub................ 6-20 Hydraulic Brake Caliper.........
  • Page 95 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Drive System Front Drive Actuator/Differential Lock  NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.  NOTE: The actuator is not a serviceable compo- ...
  • Page 96 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AG928 AG926  NOTE: It is important to tighten this cap screw while INSTALLING the others are loose to ensure proper seating of the  NOTE: Make sure to properly align the differential actuator.
  • Page 97 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut and washer. AF896D 10. Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft;...
  • Page 98 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF897D PR725A 14. Remove the upper A-arm lock nuts and cap screws; 16. Remove the inner fender panels. then remove the A-arms. 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case;...
  • Page 99 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD016 GC004A 20. Free the differential assembly from the frame mount- 2. Using a rubber mallet, remove the housing. Account ings; then shift the differential assembly forward for a gasket. Remove the fork, collar, and spring.
  • Page 100 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD107 KX219 5. Using a seal removal tool, remove the input shaft Assembling Input Shaft seal. Account for a spacer. 1. Place the pinion housing in a press and install the input shaft bearing.
  • Page 101 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC014 CD099 3. Lubricate the input shaft with High-Performance #2 5. Place the pinion housing with new gasket onto the Molybdenum Disulphide Grease packing the boot gear case housing; then secure with the existing cap ribs and splines;...
  • Page 102 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC003 KX177 3. Using a plastic mallet, tap lightly to remove the dif- ferential cover. Account for an O-ring. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly. Account for KX174 shim(s) and mark as right-side.
  • Page 103 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Disassembling Pinion Gear  NOTE: Any service of the pinion gear or related bearings will require a new gear case/differential housing. The removal of the lock collar severely dam- ages the threads in the housing.
  • Page 104 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC884 CC891 3. Coat a new needle bearing and the bearing pocket of Shimming Procedure/Shim Selection a new gear case/differential housing with red Loctite #271; then using a suitable driver, install the bearing lightly seated against the bearing seats.
  • Page 105 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC031A GC033A 2. Install the ring gear with shim in the gear case; then 4. Install the existing shim or a 0.063 in. shim on the while holding the pinion stationary, rock the ring cover side of the ring gear;...
  • Page 106 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.
  • Page 107 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC036B CF275A 5. Making sure the O-ring is properly positioned on the  NOTE: The spider and ring gear assembly must be differential housing cover assembly, install the cover replaced as a complete unit.
  • Page 108 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb. CF278 CAUTION Make sure the tool is free of nicks or sharp edges or CD103 damage to the seal may occur.
  • Page 109 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AG925 AF896D 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this sec- tion). 6. Secure the upper A-arms with cap screws and lock nuts. Tighten to 50 ft-lb.
  • Page 110 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock. PR725A REMOVING FRONT DRIVE AXLE  NOTE: For removing a front drive axle, see Front KX041 Differential in this section.
  • Page 111 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 7. Install the wheel. Tighten to 40 ft-lb. 8. Remove the ATV from the support stand and release the brake lever lock. INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steering knuckle;...
  • Page 112 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AT THIS POINT  For servicing the input shaft, pinion gear, needle bear- ing, ring gear, and axle seal, see Front Differential in this section. RING GEAR/THRUST BUTTON Removing 1. Remove the cap screws securing the gear case cover to the gear case;...
  • Page 113 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CLEANING AND INSPECTING 3. If clearance is as specified, remove the ring gear and thrust button; then place a drop of red Loctite #271  NOTE: Whenever a part is worn excessively, on the threads and tighten to 8 ft-lb (left-hand threads).
  • Page 114 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service.
  • Page 115 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR713A PR715 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid.
  • Page 116 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR719C PR238 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.
  • Page 117 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel...
  • Page 118 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-6 Troubleshooting ............7-8 www.mymowerparts.com...
  • Page 119 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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.
  • Page 120 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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.
  • Page 121 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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 a cable tie and grommet.  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary.
  • Page 122 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF618D CD008 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten to 40 ft-lb. install the hub assembly onto the drive axle. 14. Remove the ATV from the support stand.
  • Page 123 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 9. Remove the cap screws and lock nuts securing the 7. Compress the hand brake lever and engage the brake knuckle to the A-arms. Discard the lock nuts. lever lock; then secure the hub nut (from step 5) to the drive axle.
  • Page 124 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 REMOVING 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the wheels.
  • Page 125 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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...

  • Page 126: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............2 Steering Post/Tie Rods ..........2 Handlebar Grip ............5 Steering Knuckles ............6 Measuring/Adjusting Toe-Out ........7 Front Rack ..............9 Front Bumper Assembly ..........9 Front Body Panel/Side Panels........

  • Page 127: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the reinstallable rivets securing the radiator access cover and remove the cover. Steering/Frame The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose.
  • Page 128 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 FI468 CD685 6. Remove the four cap screws securing the handlebar 9. Remove the cotter pins and slotted nuts from the caps and speedometer bracket to the steering post; inner and outer tie rod ends; then remove the tie rods...
  • Page 129 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Place the upper steering post bearings into the hous- ings; then position on the steering post and secure the housings to the frame with two cap screws. Tighten to 20 ft-lb.

  • Page 130: Handlebar Grip

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Handlebar Grip REMOVING 1. Loosen but do not remove the cap screws in the end of the handlebar; then tap lightly on the head to dis- lodge the handlebar plug. FI464A...

  • Page 131: Steering Knuckles

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Wipe off any excess glue; then secure the grip with CAUTION the handlebar end-cap. Use extreme care when removing the bearing. If the bearing is allowed to fall, it will be damaged and will Steering Knuckles have to be replaced.

  • Page 132: Measuring/Adjusting Toe-Out

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF618D PR264A 4. Apply a small amount of grease to the hub splines. 8. Pump the hand brake lever; then engage the brake lever lock. 9. Secure the hub nut (from step 6) to the shaft. Tighten to 200 ft-lb.
  • Page 133 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE047A AF786D 5. Adjust the handlebar direction until the two measure-  NOTE: The distances from the inside rims to the ments are equal; then secure the handlebar to the rear frame tubes should be equal.

  • Page 134: Front Rack

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Clean all rack components using a pressure washer. 2. Inspect all welds for cracking or bending. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals and/or reflectors.
  • Page 135 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Remove the ignition switch retaining ring and two reinstallable rivets securing the instrument pod; then remove the instrument pod. FI465A FI463A FI466A 2. Unlock the storage compartment lid; then slide the storage compartment cover assembly forward and lift off the storage compartment.
  • Page 136 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CF237A CD681 9. Rotate the handlebar to the full-left position; then lift and slide the panel to the rear and lift the rear up to clear the handlebar. FI470A 7. Remove the left and right footwells; then remove the shift knob.
  • Page 137 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Connect the headlight connectors to the appropriate headlights and the front accessory plug wires to the accessory plug. FI468 CD681 3. Make sure the rubber grommets and bushings are in place;...

  • Page 138: Footrests

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Place the belly panel into position on the underside of the frame; then install the machine screws and Footrests shoulder washers. Tighten securely. Exhaust System REMOVING 1. Remove the machine screws and flange nuts secur- ing the front and rear fenders to the footwells.

  • Page 139: Taillight Assembly

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING 2. Remove one shoulder screw and lock nut and three plastic rivets (on each side) securing the rear body 1. Remove the gas tank cap and set the rear body panel panel to the footwells.

  • Page 140: Seat

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the torx-head cap screws securing the tail- light assembly to the frame. Account for any wash- ers. 3. Remove the taillight assembly. INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary.

  • Page 141: Troubleshooting

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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.
  • Page 142 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-3 Shift Lever ............... 9-4 LCD Gauge ............. 9-4 www.mymowerparts.com Manual Table of Contents...

  • Page 143: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the Hand Brake pivot pin hole in the housing; then lay it aside Lever/Master Cylinder leaving the switch and wiring harness connected.

  • Page 144: Throttle Control

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING Throttle Control 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar.

  • Page 145: Shift Lever

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING INSTALLING 1. Place the return spring into the throttle control; 1. Place the spring into position between the upper then place the bushing and actuator arm into posi- shift arm and shift lever; then making sure the tion.

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