Arctic Cat HDX CREW 2017 Service Manual
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Arctic Cat HDX CREW 2017 Service Manual

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ERVICE
ERVICE
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ANUAL
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Summary of Contents for Arctic Cat HDX CREW 2017

  • Page 1 2017 ERVICE ERVICE ANUAL ANUAL ™ ™ www.arcticcat.com...

  • Page 2: Table Of Contents

    2017 HDX Crew Service Manual Table of Contents General Information/Foreword ........2 Fuel/Lubrication/Cooling..........88 Specifications ............... 2 Throttle Body ...............88 Torque Specifications............ 3 Gas Tank ..............89 Torque Conversions (ft-lb/N-m)........4 Oil Pump ..............91 Gasoline - Oil - Lubricant..........4 Liquid Cooling System ..........91 Preparation For Storage ..........

  • Page 3: General Information/Foreword

    When replacement of parts is necessary, use only genuine Ignition Coil Resistance (primary) Less than 1 ohm Arctic Cat parts. They are precision-made to ensure high (secondary) quality and correct fit. Refer to the appropriate Illustrated Ignition Coil Primary Voltage...

  • Page 4: Torque Specifications

    CYLINDER, PISTON, AND RINGS STEERING COMPONENTS Piston Skirt/Cylinder Clearance (max) 0.052 mm Torque Part Part Bolted To Cylinder Bore 101.992-102.008 mm ft-lb Piston Diameter 15 mm from Skirt End 101.956-101.994 mm Steering Wheel** Steering Shaft Piston Ring Free End Gap (1st/2nd) 12.5 mm Rack and Pinion Assembly Frame...

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

    ENGINE/TRANSMISSION Torque Conversions (ft-lb/ Torque Part Part Bolted To N-m) ft-lb Engine Cradle/Rubber Mount Rubber Mount/Frame Engine Cradle Engine Cam Sprocket** Camshaft 13.5 ft-lb ft-lb ft-lb ft-lb Cylinder (6 mm) Crankcase 13.5 35.4 69.4 103.4 Valve Cover Cylinder Head 11.5 36.7 70.7 104.7...

  • Page 6: Preparation For Storage

    CAUTION Arctic Cat recommends the following procedure to pre- Do not use white gas. Only Arctic Cat approved gaso- pare the vehicle for storage. An authorized Arctic Cat line additives should be used.
  • Page 7 3. Check all control wires and cables for signs of wear 8. Check the tire pressure. Inflate to recommended or fraying. Replace if necessary. pressure as necessary. 4. Change the engine/transmission oil and filter. 9. Tighten all nuts, bolts, cap screws, and screws mak- ing sure all calibrated nuts, cap screws, and bolts are 5.

  • Page 8: Periodic Maintenance/Tune-Up

    HDX050A NOTE: Cleaning Solvent and Aerosol Air Filter Oil  are available from Arctic Cat. 4. In a pan larger than the element, with a mild deter- gent (dish soap) and water, wash all the dirt and oil off by squeezing the element. Ringing or twisting the HDX237A filter may cause damage.

  • Page 9: Valve/Tappet Clearance

    6. Remove any excess water from the element by blot- ting with a towel. Valve/Tappet Clearance 7. Allow the element to dry completely. 8. Spray oil generously onto air filter and work the oil NOTE: The engine must be cold for this procedure. ...

  • Page 10: Testing Engine Compression

    NOTE: Refer to the specifications in CHECKING 7. Pour approximately 30 ml (1 fl oz) of oil into the  spark plug hole, reattach the gauge, and retest com- for the proper valve/tappet clearance. pression.  NOTE: Rotating the valve adjuster dial counter- 8.

  • Page 11: Engine/Transmission Oil - Filter

    1. Remove the cap screws securing the spark arrester 4. Apply fresh oil to a new filter O-ring and check to screen assembly to the muffler; then loosen and make sure it is positioned correctly; then install the remove the spark arrester. Account for a gasket and new oil filter.

  • Page 12: Front Differential - Rear Drive Lubricant

    GZ461A HDX255 CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is not above the upper mark. 10. Inspect the area around the drain plug and oil filter for leaks. Front Differential - Rear Drive Lubricant To check lubricant, use the following procedure.

  • Page 13: Headlight/Taillight-Brakelight

    1. Position the vehicle on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming sur- Headlight - Taillight/ face (wall or similar aiming surface). Brakelight HEADLIGHT  NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE.

  • Page 14: Hydraulic Brake System

    PR920 HDX261B Move the shift lever all the way back. The letter L should 4. Install the E-clip; then tighten the nuts (A) and (B) to illuminate on the LCD gauge. 8 ft-lb. 5. Check each gear shift position for proper gear selection and make sure the proper icon illuminates on the LCD.
  • Page 15 3. Carefully check the entire hydraulic brake system to ensure all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present. CAUTION This hydraulic brake system is designed to use DOT 4 brake fluid only.

  • Page 16: Burnishing Brake Pads

    C. Secure the caliper holder to the knuckle with new patch-lock cap screws. Tighten to 20 ft-lb. “ ” HDX258A 4. Remove the cap screws securing the support tube to the frame. HDX345A 5. Install the wheels and using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/...
  • Page 17 CHECKING Use Drive Belt Gauge to identify any abnormal wear. Measure across the top of the V-belt (in multiple loca- tions) using a Vernier caliper. Do not squeeze the belt as doing so may produce an inaccurate measurement. The V-belt must be at least 35.0 mm at any point. INSTALLING 1.
  • Page 18 CF379 H1-017 5. Install the support tube to the frame; then position NOTE: At this point, the CVT cover cap screw can  the intake duct and tube in place. Secure with the cap be removed. screw, lock nut, and clamp. 3.

  • Page 19: Steering/Body/Controls

    Steering/Body/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full- right turning capability. C. Steering sector mounting bolts tight. D. Ball joints not worn, cracked, or damaged. PR899 E.
  • Page 20 PR776A PR917 4. Install the cap screws securing the EPS assembly to 7. Disconnect the two EPS connectors. the frame and tighten to 35 ft-lb. Install the cap screw and new lock nut in the EPS to rack coupler 8. Remove the cap screws securing the EPS assembly and tighten to 11 ft-lb.
  • Page 21 INSTALLING RACK AND PINION 12. Install the front access panel, front fenders, and hood. 1. From the left side, install the steering assembly (rack and pinion) to the frame assembly and secure with 13. Install the steering wheel (see Steering Wheel in this two cap screws.

  • Page 22: Steering Knuckles

    NOTE: Tie rods come as a complete assembly. No 6. Center the rack in the steering rack assembly and  align the white paint line on the pinion with the mark further disassembly is required. on the rack housing. 5. Remove and discard the lock washer. INSTALLING 1.
  • Page 23 PR289 PR202 CLEANING AND INSPECTING 1. Clean all knuckle components. 2. Inspect the bearing for pits, scoring, rusting, or pre- mature wear. 3. Inspect the knuckle for cracks, breaks, or galling of the bearing surface. ASSEMBLING AND INSTALLING 1. Using a suitable press and driver, press the bearing into the knuckle until firmly seated;...

  • Page 24: Accelerator Pedal

    9. Install the wheels and using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/ chrome nuts). 10.

  • Page 25: Shift Cable

    3. Remove the cap screw and lock nut securing the shift lever to bottom pivot location (underneath the dash- board). Slide the shift lever down and out. Discard the lock nut. HDX261A 4. Remove the E-clip securing the cable end to the shift arm stud.

  • Page 26: Lcd Gauge

    LCD Gauge REMOVING/INSTALLING To remove the gauge, pull out on one side of it; then dis- connect the multi-pin connector and remove the gauge. HDX262B 2. Guide the shift cable into the shift cable bracket. Install the cable end to the shift arm stud and secure with a new E-clip.

  • Page 27: Front Fascia/Front Bumper

    PR087A PR890A 1. Center the steering wheel; then using an open-end 2. Remove the cap screws securing the outer fender; wrench to hold the tie rod ends, loosen the right-side then remove the inner front fenders from both sides and left-side jam nuts. of the vehicle.
  • Page 28 HDX304 HDX307A HDX305A HDX308 5. Remove the cap screws and nuts securing the top INSTALLING side of the radiator to the front bumper. Disconnect 1. Place the front bumper into position and secure with the radiator fan connector. Secure the radiator in the four cap screws and new lock nuts.

  • Page 29: Hood

    2. From under the hood, install the two cap screws securing the bottom of the front storage box to the front bumper. Using the previously marked harness anchor locations, install the anchors to the front bumper. 3. Secure the radiator to the front bumper and connect the radiator fan to the wiring harness.

  • Page 30: Floor

    2. Remove the push pins securing the front access panel. Tilt the access panel back to access the inner fender fasteners. HDX132A 2. Remove the cap screws securing both front side pan- els. PR890A 3. Remove the remaining cap screws securing the inner fender from the inside of the headlight assembly, storage tray, and frame.
  • Page 31 4. Remove the cap screws securing the second row kick panels to both center side panels; then remove the remaining cap screws securing both center side pan- els to the frame. PR164 7. From the opposite side of the vehicle, repeat step 6; then lift the rear of the floor up and lift the floor out of the vehicle.
  • Page 32 5. Remove the cap screws securing the center footrest to the frame and support bracket; then remove the four cap screws securing the rear floorboard to the second row front kick panel. HDX351A 2. Remove the rear seat, seat back, and seat base. 3.
  • Page 33 HDX356A HDX357 8. While pulling forward on the upper rear portion of Cleaning and Inspecting the floorboard, lift the rear part of the floor above the 1. Clean the floor with soap and water. seat locating studs. 2. Inspect the floor for cracks or holes. Installing 1.

  • Page 34: Side Restraint Latches

    HDX353A HDX347A 5. Install the four cap screws securing the front of the 7. Install the seat base, seat back, and both rear side floor to the second row forward kick panel. panels. HDX354A HDX351A 6. Secure both steel kick panels to the frame; then place 8.

  • Page 35: Dashboard

    CENTER HDX344A HDX268A 3. Remove the cap screws around the perimeter of the INSTALLING dashboard. 1. Secure the latch to the frame with new cap screws and lock nuts. 2. Install the front row plastic side panels (center); then secure with the cap screws. 3.

  • Page 36: Belly Panel

    HDX270 HDX268A 7. Slowly pull away the top of the center dash pad and remove the final cap screw. Remove the dashboard. HDX267A 7. Install the front access panel, hood seal, and shift lever knob. HDX271 8. Align and install the steering wheel (see Steering INSTALLING Wheel in this section).

  • Page 37: Cargo Box

    HDX286 HDX257 2. From the rear of the vehicle, lifting up to clear the 3. Loosen but do not remove the four shoulder cap sway bar, slide the muffler out. screws securing the pivot housings to the cargo box. INSPECTING 1.

  • Page 38: Taillight Assembly

    Taillight Assembly Seat Backs REMOVING REMOVING/INSTALLING 1. Remove the cap screws and lock nuts securing the 1. To remove the first and second row seat backs, taillight assembly to the ROPS tube. remove the four cap screws securing the seat back to the frame;...

  • Page 39: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Steering shaft binding 2. Lubricate/replace steering shaft 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 40: Engine/Transmission

    Piston Pin Puller 0644-328 Secondary Drive Gear Holder 0444-253  NOTE: Arctic Cat recommends the use of new gas- Spanner Wrench 0444-240 kets, lock nuts, and seals and lubricating all internal Surface Plate 0644-016 components when servicing the engine/ transmission.

  • Page 41: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace guides 3. Valves mistimed 3. Retime engine 4. Piston rings worn - broken 4.
  • Page 42 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 43: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service/replace right- side cover oil seals, front output joint oil seal, rear out- HDX138A put joint oil seal, and/or the oil strainer (from beneath 6.
  • Page 44 8. Loosen the clamp securing the throttle body to the intake manifold boot; then remove the throttle body and set aside. 9. From the left side, disconnect the ECT sensor con- nector, speed sensor connector, and spark plug cap. HDX149A 12.
  • Page 45 HDX154 HDX158A 14. Disconnect the oxygen sensor; then remove the oxy- gen sensor. HDX159A 17. Remove the cap screws and lock nuts securing the rubber coupler to the drive flange located at the front HDX247 of the engine and center propeller shaft. Remove the rubber coupler.

  • Page 46: Installing Engine/Transmission

    Account for the spacers. Discard the lock nuts. Installing Engine/ Transmission NOTE: Arctic Cat recommends new gaskets and O-  rings be installed whenever servicing the vehicle. 1. Place the engine spacers in position; then using new...
  • Page 47 HDX277 HDX410A 5. Insert the rubber coupler between the center propel- ler shaft and the drive flange located at the front of the engine. Secure using new cap screws and lock nuts. HDX363A 8. Place a new grafoil gasket in the cylinder head and a new grafoil seal on the muffler end of the exhaust pipe and install the exhaust pipe.
  • Page 48 10. Install the forward exhaust pipe heat shield and secure with the machine screws. Tighten securely. HDX149A 13. Properly position the gear position switch on the engine (A to A and B to B); then secure the shift HDX152A cable bracket to the engine case and tighten the 11.
  • Page 49 HDX359 HDX138B 15. Install the throttle body into the intake manifold boot 19. Connect the MAP sensor connector (A), fuel injector and secure with the clamp. Tighten to 30 in.-lb. connector (B), ISC connector (C), and TPS connec- tor (D); then install new nylon ties as noted during 16.

  • Page 50: Servicing Engine

    Servicing Engine Removing Top-Side Components ....... 49 Servicing Top-Side Components ........ 52 Installing Top-Side Components ......... 57 Removing Left-Side Components....... 61 Servicing Left-Side Components ........ 63 Installing Left-Side Components......... 65 Removing Right-Side Components ......68 Servicing Right-Side Components......70 Installing Right-Side Components ......75 H1-013A Center Crankcase Components .........
  • Page 51 6. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. NOTE: Care should be taken not to drop the C-ring  down into the crankcase. H1-037A 10. Remove the five nuts securing the cylinder head to the cylinder.
  • Page 52 AT THIS POINT  To service valves and cylinder head, see Servicing Top- Side Components sub-section. AT THIS POINT  To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC025D CC022D C. Cylinder D. Piston NOTE: Steps 1-12 in the preceding sub-section must ...

  • Page 53: Servicing Top-Side Components

    CC033D CC130D CAUTION  NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Con- Water or parts-cleaning solvent must be used in con- necting Rod Holder. junction with the wet-or-dry sandpaper or damage to the sealing surface may result.
  • Page 54 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- CC132D nents be taken to a qualified machine shop for servicing. PISTON ASSEMBLY NOTE: Whenever a piston, rings, or pin are out of ...
  • Page 55 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must not exceed speci- fications. CC127D 2. Measure the corresponding piston diameter at the recommended point above the piston skirt at a right angle to the piston-pin bore. Subtract this measure- CC280D ment from the largest measurement in step 1.
  • Page 56 Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 3. Maximum distortion must not exceed specifications. ATV-1024B CAUTION Incorrect installation of the piston rings will result in...
  • Page 57 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° from the first measurements for a total of six measurements.

  • Page 58: Installing Top-Side Components

    3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
  • Page 59 10. Using a crisscross pattern, tighten the four cap screws (from step 8) initially to 20 ft-lb; then in 10 ft-lb increments, tighten to a final torque of 40 ft-lb. 11. Tighten the 8 mm nuts from step 9 to 18 ft-lb and the 6 mm nuts to 10 ft-lb;...
  • Page 60 CD463 ATV1027 16. Seat the cam sprocket onto the camshaft making sure CAUTION the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the cam- Care must be taken that the tab-washer is installed cor- shaft/sprocket assembly onto the cylinder ensuring rectly to cover the alignment hole on the sprocket.
  • Page 61 CD466 CD501 21. Place the C-ring into position in its groove in the cyl-  NOTE: The adjuster shaft will be drawn into the inder head. tensioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 25. 24.

  • Page 62: Removing Left-Side Components

    CD471 CC003D 26. Loosen the four adjuster screw jam nuts; then loosen 30. In a crisscross pattern starting from the center and the four adjuster screws on the rocker arms in the working outward, tighten the cap screws (from step valve cover.
  • Page 63 NOTE: It may be necessary to use a small two-jaw  puller to remove the trigger. PR441 H1-030 CD939A GZ254 4. Loosen the clamps securing the coolant hose to the water pump; then remove the crossover tube from the cylinder head. Account for an O-ring. 5.

  • Page 64: Servicing Left-Side Components

    CD140 PR430A 11. Remove the snap ring securing the water pump drive 14. Remove the gear shift cam plate and account for a gear; then remove the gear noting the direction of the washer; then remove the cam stopper and cam stop- sides of the gear for installing purposes.
  • Page 65 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING 1. Support the starter clutch gear in a press making sure to support the hub around the entire circumference;...

  • Page 66: Installing Left-Side Components

    REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor.
  • Page 67 CD944 CD948A  NOTE: The sharp side of the snap ring should be facing outward.  NOTE: Once the gears are secured, remove the oil passage plug from the crankcase. 3. Install the two starter gear shafts; then install the two starter gears.
  • Page 68 PR434A PR431A 9. Install the magneto cover and secure with the cap  NOTE: Rotate the shift cam plate to ensure it ratch- screws. Tighten only until snug. ets with no binding. 10. Place the bushing into position on the crankshaft 7.

  • Page 69: Removing Right-Side Components

    H1-030 CF373A 14. Place the water pump into position and secure with two cap screws. Tighten to 8 ft-lb. NOTE: Ensure the slotted water pump shaft is  aligned with the groove in the counter balancer shaft. 15. Install the crossover tube on the water pump and cyl- inder head making sure the O-ring is properly posi- tioned.
  • Page 70 CD973A CC596 CAUTION  NOTE: Account for and inspect the clutch housing seal. Care must be taken when removing the cover so the cover gasket is not damaged. NOTE: For steps 7-13, refer to illustration H1-  029A. NOTE: To aid in installing, it is recommended that ...

  • Page 71: Servicing Right-Side Components

    13. Using an impact driver, remove the three torx-head screws securing the oil pump; then remove the pump. CC606 11. Using an impact wrench, remove the cap screws securing the final drive carrier bearing housing (D); then remove the housing and account for two align- ment pins.
  • Page 72 INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. ATV1152A 3. Check the internal bushing of the movable drive sheave and surface of the spacer.
  • Page 73 CF381 WC418A 4. Turn the wing nut counterclockwise to relax the DRIVEN CLUTCH ASSEMBLY spring. As the cam clears the key in the fixed driven shaft, there will be a slight clockwise rotation of the Disassembling cam. This is normal due to spring preload. 1.
  • Page 74 WC383 WC383A 2. Inspect the cam shoes on the movable driven sheave 6. Inspect the spring for kinks by rolling on a flat sur- for chipping, excessive scoring, or general condition. face. The spring should roll freely with no irregulari- ties.
  • Page 75 WC414 WC388 6. Turn the wing nut clockwise to compress the spring 3. Install the spring over the hub of the movable driven being very careful that the cam correctly engages the sheave engaging the spring into the previously fixed driven hub; then continue to tighten until the marked spring anchor hole.

  • Page 76: Installing Right-Side Components

    WC412 CD999 2. Install the oil pump; then tighten the screws (coated with red Loctite #271) to 8 ft-lb. WC419 9. Turn the wing nut counterclockwise slowly allowing the cam to contact the snap ring; then loosen slightly and tap the cam with a plastic mallet to ensure the CD988 snap ring is securely seated.
  • Page 77 CD991 PR410A 4. Grease the driven gear pin and insert it into the shaft. 6. Install the clutch cover alignment pins into the crank- Install the washer; then install the driven gear noting case, apply oil to the cover gasket, and install the the direction on the sides of the gear from removing).
  • Page 78 H1-023 PR389 10. Place the driven pulley assembly into position and NOTE: The arrows on the V-belt should point in the  secure with the nut. Tighten to 162 ft-lb. direction of rotation. 14. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft.

  • Page 79: Center Crankcase Components

    16. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws with Disassembling Crankcase fibrous washers making sure the different-lengthed Half cap screws are in their proper location. Tighten the cap screws to 44 in.-lb. ...
  • Page 80 3. Remove the shift shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes. 4. Remove the gear shift shaft (G) noting the location of the two holes on the end of the shaft. Account for a spacer and a washer.

  • Page 81: Servicing Center Crankcase Components

    CAUTION Unless the secondary drive gear, bevel gear, or bear- ings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear back- lash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. 13.
  • Page 82 NOTE: Do not use a new lock nut at this time as this 1. If backlash measurement is less than specified,  remove an existing shim, measure it, and install a procedure may have to be repeated. new thinner shim. 5.
  • Page 83 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. H1-005 2. Acceptable width range must not exceed specifica- tions. CC289D 3. Acceptable gap range must not exceed specifica- COUNTERSHAFT tions. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2.
  • Page 84 GZ296 GZ320 GZ312 GZ319 3. Remove the reverse driven gear dog. GZ318A 6. Remove the low driven gear. Account for a bearing, GZ313A bushing, and thrust washer. 4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear. GZ316 GZ314 Assembling...
  • Page 85 GZ317A GZ286A GZ318 GZ287 2. Install the low driven gear locking washer; then 4. Install the outer reverse driven washer; then secure install the inner reverse driven gear washer. the reverse driven gear assembly with a snap ring. GZ319B GZ288A GZ320B GZ314 3.

  • Page 86: Assembling Crankcase Half

    GZ313A MT014 2. Apply a liberal amount of engine oil to the crank- shaft bearing. Using a propane torch, heat the bear- ing until the oil begins to smoke; then slide the crankshaft assembly into place. GZ312 6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F).
  • Page 87 CD832B CC674 7. Place a washer on the end of the gear shift shaft; then  NOTE: It will be necessary to rotate the crank bal- install the shaft assembly making sure the two holes ancer until the counterweight is facing away from the on the end of the shaft are positioned vertically.

  • Page 88: Joining Crankcase Halves

    2. Lightly oil all bearings and grease all shafts in the right-side crankcase. 3. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 4. From the right side, install the 8 mm cap screws; then tighten only until snug.

  • Page 89: Fuel/Lubrication/Cooling

    3. Remove the air inlet boot between the air filter and throttle body; then disconnect the MAP sensor con- Fuel/Lubrication/ nector (A), fuel injector connector (B), ISC connec- Cooling tor (C), and TPS sensor connector (D). TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by lis- tening for a “whirring”...

  • Page 90: Gas Tank

    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. REMOVING 1. Remove the rear seat, seat back, seat base, and side panels;...
  • Page 91 HDX369A HDX370 2. Install the front hold-down strap and secure with the two cap screws. HDX370 5. Lift and slide the tank forward raising the front of the tank first; then turn the tank and lift out the right HDX368 side.

  • Page 92: Oil Pump

     NOTE: Some oil seepage may occur when installing the oil pressure gauge. Wipe up oil residue with a When filling the cooling system, use premixed Arctic Cat cloth. Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, open the bleed screw on 3.
  • Page 93 CAUTION After operating the vehicle for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary. RADIATOR Removing 1. Open the hood and remove the weather strip; then remove the front access panel, front fenders, and front storage box.
  • Page 94 8. Allow engine and coolant to cool to room tempera- ture; then verify the coolant level in the reservoir tank is at the MIN mark. Add coolant as necessary. PR184A 2. Secure the oil cooler to the radiator with four screws, two located on each side.

  • Page 95: Troubleshooting

    Installing 1. Place the thermostat with seal into the thermostat housing; then secure the thermostat housing to the cylinder head with the two cap screws. CAUTION When installing the thermostat, make sure the bleed holes are straight up and down or air will remain trapped causing engine damage due to overheating.

  • Page 96: Electrical System

    Maintenance Charging Description  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for Fluke Model 77 Multimeter 0644-559 battery maintenance charging. Maintenance charging...

  • Page 97: Electronic Power Steering (Eps)

    CATT II software. The following Charging is a list of DTCs, possible conditions, and causes. NOTE: Arctic Cat recommends the use of the  NOTE: If no active codes are present on the LCD or ...
  • Page 98 Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1301 Over Current EPS internal over-current condition has Internal EPS Condition Correct EPS condition* been detected C1302 Excessive Current Error EPS internal current measurement error Internal EPS Condition Correct EPS condition* has been detected C1303 Torque Sensor Range EPS internal torque sensor range...

  • Page 99: Ignition Switch

    TROUBLESHOOTING NOTE: If the meter shows no battery voltage, trou-  bleshoot the main 30 amp fuse, the battery, or the  NOTE: The EPS assembly is not serviceable and main wiring harness. must not be disassembled or EPS warranty will be 4.

  • Page 100: Ignition Timing

    If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil bracket may be bent or damaged, or the ECM may be faulty. Accessory Receptacle/ Connector NOTE: This test procedure is for either the recepta- ...
  • Page 101 3. Meter reading should show less than one ohm. 4. Release the seat belt latch from the buckle while the meter leads are connected to the pins. Meter reading should show OFL. NOTE: If the meter readings are OFL or greater ...

  • Page 102: Fan Motor

    NOTE: If the meter does not show battery voltage, 2. Select the DC Volts position on the tester and  observe the meter readings for each of the three troubleshoot the LIGHTS fuse on the power distribu- switch positions. tion module, the ignition switch, or the main harness. 3.

  • Page 103: Lights

    2. Connect the black tester lead to the black wire; then connect the red tester lead to the white/red wire. The meter should show battery voltage. 3. With the ignition key in the LIGHTS position, the meter must show battery voltage. NOTE: If battery voltage is not shown and the head- ...

  • Page 104: Efi Sensors/Components

    AC Voltage 3. Connect the black tester lead to battery ground.  NOTE: The battery must be at full charge for these 4. Using the red tester lead, contact each end of the fuse tests. holder connector terminals individually. 5. The meter must show battery voltage from one side 1.

  • Page 105: Speed Sensor

    MANIFOLD ABSOLUTE PRESSURE/ NOTE: Neither the sensor nor the thermometer  should be allowed to touch the bottom of the con- INLET AIR TEMPERATURE (MAP/IAT) tainer or inaccurate readings will occur. Use wire SENSOR holders to suspend the sensor and thermometer. ! WARNING Wear insulated gloves and safety glasses.
  • Page 106 FUEL PUMP/FUEL LEVEL SENSOR Removing The fuel pump and fuel level sensor are not serviceable 1. Remove the key from the ignition switch. components. If either component fails, it must be replaced. ! WARNING Testing Always ensure that power cannot be inadvertently applied to the ignition/ECM when working on the fuel ! WARNING system.

  • Page 107: Tilt Sensor

    2. Slide the existing sender assembly (B) up and off the NOTE: It is important to install the fuel pump with  fuel pump assembly housing. the correct orientation to ensure adequate float lever clearance. 2. Connect the gasline hose to the fuel pump pipe and secure with the hose clamp;...
  • Page 108 THROTTLE POSITION SENSOR (TPS) Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section). Verifying TPS Adjustment Tool Before using the TPS adjustment tool, verify its battery condition.

  • Page 109: Rpm Limiter

    3. Using a multimeter, connect the tester to the analyzer Incorrect as shown in the table below; then select the DC Volt- Fail- High/ ECU/ age position. With the vehicle off and throttle at idle, Gear Park Neutral Reverse Safe Gauge Mode the gauge should read as shown and at Wide-Open...

  • Page 110: Regulator/Rectifier

    3. Repeat test for each black wire. NOTE: The ignition switch must be in the ON posi-  tion, and the shift lever in the NEUTRAL position. 1. Set the meter selector to the DC Voltage position. Regulator/Rectifier 2. Connect the red tester lead to the starter terminal; then connect the black tester lead to ground.

  • Page 111: Electronic Control Module (Ecm)

    NOTE: If a “click” is heard and more than one volt 4. Turn the key to the OFF position and allow the gauge  to shut off. is indicated by the multimeter, replace the starter relay. If no “click” is heard and the multimeter con- tinues to indicate battery voltage, proceed to step 4.
  • Page 112 2. Battery voltage with engine idling (charging = 13.8 NOTE: After engine has been running, IAT read-  VDC or greater). ings will be higher than outside air temperature due to engine and engine compartment heat as well as 3. Battery voltage with electrical accessories operating, intake manifold heating.
  • Page 113 TPS (TPS) Display: Engine RPM DTC: P0336, P0337, P0339 Usage: Verify engine speed signal from the following. 1. CKP (crankshaft position) sensor to ECM 2. ECM (CAN) signal to gauge (tachometer) 3. ECM (CAN) signal to EPS Speedometer (SPEED) WT539 Display: TPS position (0% closed, 95-100% WOT).
  • Page 114 Code Fault Description Possible Cause Fault Recovery Method C0063 Tilt Sensor Circuit High Sensor or interconnect harness shorted to battery power Correct condition* C0064 Tilt Sensor Circuit Low/SG/Open Sensor or interconnect harness open or shorted to chassis ground Correct condition* P0030 O2 Heater Intermittent/Open Heater or interconnect harness intermittent or open...
  • Page 115 Code Fault Description Possible Cause Fault Recovery Method P0616 Starter Relay Circuit Low Start switch/button, starter relay or interconnect harness Correct condition* intermittent or shorted to chassis ground P0617 Starter Relay Circuit High Start switch/button, starter relay or interconnect harness Correct condition* intermittent or shorted to battery power P0630...

  • Page 116: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.

  • Page 117: Drive System

    2. Using a T-30 torx wrench, remove the mounting cap screw from the driveshaft side of the actuator. Drive System GENERAL INFORMATION Gear cases are 3.6:1 ratio. The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing;...

  • Page 118: Front Differential

    Front Differential REMOVING 1. With the vehicle on a lift or support stands, elevate the wheels off the ground. 2. Remove the hubs (see Hub in this section). 3. Remove the belly panel. 4. Remove the drain plug and drain the gear lubricant into a drain pan;...
  • Page 119 7. Pull the steering knuckle away from the axle. HDX292 12. Remove the upper differential mounting cap screw. PR222 Account for a lock nut and two washers. 8. Support the axle to prevent it from dropping or hang- ing. CAUTION The axle must be supported.
  • Page 120 HDX379A XR352 17. Free the differential assembly from the frame mount- 3. Remove the snap rings from the input shaft; then ings and separate from the front driveshaft; then remove the input shaft from the pinion housing. lower the differential through the frame. Disassembling Input Shaft NOTE: This procedure can be performed on a rear ...
  • Page 121 XR350 GC014 3. Lubricate the input shaft with High-Performance #2 Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess grease to freely escape. Slight pressure on the boot will be present during assembly. Secure with new clamps.
  • Page 122 GZ004A XR356 5. Remove the left differential bearing flange assembly Disassembling Differential Assembly and account for a shim. Mark the shim as left-side. NOTE: This procedure can be performed on a rear  gear case. 1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing.
  • Page 123 KX181 CC879 4. Remove any reusable parts from the gear case hous- Disassembling Pinion Gear ing; then discard the housing and lock collar. 1. Remove the internal snap ring securing the pinion Assembling Pinion Gear bearing in the housing. 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar.
  • Page 124 3. Using a propane torch, heat the gear case housing to approximately 200° F; then install the pinion assem- bly. 4. Install the internal snap ring with the sharp side directed away from the bearing. GC031A 2. Install the ring gear with shim in the gear case; then while holding the pinion stationary, rock the ring gear forward and back to determine if any backlash exists.
  • Page 125 GC033A GC039A 4. Install the existing shim or a 0.063 in. shim on the 6. Zero the dial indicator; then while holding the pinion cover side of the ring gear; then place the assembled stationary, rock the ring gear assembly forward and gear case cover onto the gear case and secure with back and record the backlash.
  • Page 126 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness. NOTE: Once proper backlash and end play are  established, the gear case can be assembled. Assembling Differential Assembly 1. With the pinion gear and new bearings installed, place the selected (backlash) shim on the gear case side of the ring gear with the chamfered side toward the ring gear;...
  • Page 127 XR354 XR360 7. Install the shift fork assembly making sure the fork  NOTE: Prior to installing the seal, apply High-Per- leg is facing upward. Apply a small amount of oil to formance #2 Molybdenum Disulphide grease to the the gasket; then install the gasket. seal outside diameter.
  • Page 128 3. Place the carrier bearing assembly bracket into the frame and loosely install new cap screws and lock nuts. HDX378A 7. Pour 275 ml (9.1 fl oz) of SAE 80W-90 hypoid lubri- cant into the differential and install the fill plug. Tighten to 16 ft-lb.

  • Page 129: Center/Front Propeller Shaft/Carrier Bearing Assembly

    HDX293 HDX378 11. Connect the front drive actuator connector to the 4. Remove the center propeller shaft and rubber cou- main harness; then secure the wires to the frame with pler. Note the orientation of these components for nylon ties. assembly purposes.

  • Page 130: Drive Axles

    8. Tighten the cap screws securing rear rubber coupler to the front engine drive flange to 50 ft-lb. HDX395A INSTALLING NOTE: To aid in the alignment of the propeller HDX361  9. Tighten the cap screws and lock nuts securing the shafts and front engine drive flange, elevate the vehi- center rubber coupler to each propeller shaft to 50 ft- cle off the floor with a suitable lift or jack and jack...
  • Page 131 PR962 CD019 3. While holding the drive axle stationary, pull the top 2. Inspect boots for any tears, cracks, or deterioration. of the knuckle out and down until it is free of the NOTE: If a boot is damaged in any way, it must be ...
  • Page 132 4. Check the condition of the circlip on the end of the half shaft and replace if necessary. Engage the exter- nal splines on the end of the half shaft into the star- shaped inner race of the CV joint; then grasp the half shaft and seat it into the CV joint assembly by press- ing it firmly into the CV joint assembly.

  • Page 133: Rear Gear Case

    4. Install the wheels and using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/ chrome nuts). 5.
  • Page 134 2. Inspect the thrust button for excessive wear or dis- coloration. 3. Inspect the bearings for discoloration, roughness, or excessive wear. Installing/Shimming NOTE: Ring gear clearance must be adjusted prior  to selecting shim for the thrust button. 1. Install the thrust button with shim into the gear case cover and tighten securely (left-hand threads).
  • Page 135 2. Using a suitable seal driver, install a new oil seal into the front of the input housing until the seal is flush with the housing. HDX384 4. Remove the snap ring retaining the input bearing and using an appropriate bearing driver, press the bearing from the housing.

  • Page 136: Hub

    2. Lubricate the splines of the driveshaft with the appropriate grease; then align and engage the drive- line flange to the engine flange. Tighten to 20 ft-lb. 3. Secure the differential to the frame/frame bracket with two through-bolts and secure with lock nuts and flat washers.

  • Page 137: Hydraulic Brake Caliper

    7. Remove the vehicle from the support stand. Hydraulic Brake Caliper ! WARNING Arctic Cat recommends only authorized Arctic Cat ROV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 138 2. Drain the brake fluid from the caliper, hose, and mas- ter cylinder through the bleed screw by pumping the brake pedal. PR238 5. Remove the caliper holder from the caliper and dis- card the O-ring. PR235 CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle and do not reuse brake fluid.
  • Page 139 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury. 7.
  • Page 140 NOTE: It is very important to apply silicone grease 8. Fill the reservoir; then bleed the brake system (see  Periodic Maintenance/Tune-Up - Hydraulic Brake to the O-rings and caliper bores prior to assembly. System). ! WARNING Never use brake fluid from an open container or reuse brake fluid.
  • Page 141 4. Remove the master cylinder. Discard the three crush washers. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle. Inspecting 1. Inspect the master cylinder push rod and clevis for wear, bending, or elongation of clevis holes. 2.

  • Page 142: Troubleshooting Drive System

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

  • Page 143: Suspension

    To adjust the spring force on these shock absorbers, rotate the pre-load adjustment sleeve with a suitable Suspension spanner wrench until desired spring tension is achieved. Position Spring Force Setting Load The following suspension system components should be Soft Light inspected periodically to ensure proper operation.
  • Page 144 4. Using a suitable shock spring compressor, compress the shock absorber spring, remove the spring retainer, and remove the spring. ! WARNING Shock absorber springs are under high compression loads. Do not attempt to remove springs without an ade- quate spring compressor. Sever injury could result. Front HDX087A Shock Absorber...
  • Page 145 HDX337 HDX340 2. Compress the spring until approximately one inch of 5. Slowly decompress the spring via the shock spring clearance is obtained between the top of the spring compressors to remove tension from the spring; then and top spring retainer. remove the spring.

  • Page 146: Front A-Arms

    HDX340 HDX342 3. Place a new circlip into position (A) on the wear 5. Slowly decompress the spring via the shock spring sleeve. compressors to remove tension from the spring; then remove the spring compressor tool. Front A-Arms REMOVING 1. Remove the hubs (see Drive System). 2.
  • Page 147 PR193 HDX297 5. Tap the ball joints out of the knuckle; then remove CLEANING AND INSPECTING the knuckle. 1. Clean all A-arm components in parts-cleaning sol- 6. Remove the lower shock absorber eyelet from the vent. upper A-arm. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes.
  • Page 148 HDX296 HDX387 3. Route the brake hose along the upper A-arm. Secure 8. Apply grease to the hub and drive axle splines; then with hose anchors and the clamp. install the hub (see Drive System). HDX295A PR290A 4. Secure the lower eyelet of the shock absorber to the 9.

  • Page 149: Rear A-Arms

    A-arm; then remove the shock absorber. Discard the lock nuts. ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable vehicle opera- tion. This vehicle is equipped with low-pressure tubeless tires of the size and type listed in the General Information sec- tion.

  • Page 150: Troubleshooting

    REMOVING 2. Using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel 1. Secure the vehicle on a support stand to elevate the wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 wheels.
  • Page 151 NOTES...
  • Page 152 ©2016 Arctic Cat Inc. Effective: June 2016 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-902...

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