Arctic Cat VLX 70002017 Service Manual
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Arctic Cat VLX 70002017 Service Manual

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

  • Page 2: Table Of Contents

    2017 VLX 700 Service Manual Table Of Contents General Information/Foreword ........2 Fuel/Lubrication/ Cooling..........83 Specifications ............... 2 Throttle Body ...............83 Torque Specifications............ 3 Throttle Cable Free-Play ..........85 Torque Conversions (ft-lb/N-m)........4 Gas Tank ..............85 Gasoline - Oil - Lubricant..........4 Oil Pressure ..............85 Preparation For Storage ..........

  • Page 3: General Information/Foreword

    This service manual is designed primarily for use by an Gasoline (recommended) 87 Octane Regular Unleaded Arctic Cat CatMaster Basic Level technician. The proce- Engine Oil (recommended) Arctic Cat ACX All Weather dures found in this manual are of varying difficulty, and...

  • Page 4: Torque Specifications

    DRIVE TRAIN COMPONENTS (cont) Torque Specifications Torque Part Part Bolted To ft-lb N-m Thrust Button** Gear Case Cover NOTE: Torque specifications have the following tol-  Input Shaft/Housing Gear Case erances: Output Shaft** Rear Gear Case Flange Torque (ft-lb) Tolerance Bead Lock Wheel 0-15...

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

    Weather synthetic which has been specifically formu- 17.7 51.7 85.7 119.7 lated for use in this engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 20.4 54.4 88.4...

  • Page 6: Preparation After Storage

    1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. Preparation after Storage 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get Taking the ATV out of storage and correctly preparing it water into any part of the engine or air intake.

  • Page 7: Periodic Maintenance/Tune-Up

    4. Place the element in a pan larger than the element and spray both sides generously with cleaning sol- Periodic vent. Let sit approximately three minutes. Maintenance/Tune-Up NOTE: Foam Air Filter Cleaner and Foam Air Fil-  ter Oil Aerosol are available. 5.

  • Page 8: Valve/Tappet Clearance

    ADJUSTING Valve/Tappet Clearance NOTE: The seat, storage compartment cover assem-  bly, compartment box, air filter/filter housing, and left-side/right-side splash panels must be removed for this procedure. To check and adjust valve/tappet clearance, use the fol- lowing procedure. A. Place Valve Clearance Adjuster onto the jam nut 1.

  • Page 9: Spark Plug

    5. While holding the throttle lever in the full-open posi- tion, crank the engine over with the electric starter until the gauge shows a peak reading (five to 10 compression strokes). COMPRESSION PSI Hot (WOT) PSI Cold (WOT) 125-145 100-140 6.

  • Page 10: Engine/Transmission Oil - Filter

    4. Using the adjustable Oil Filter Wrench and a suitable wrench, remove the old oil filter. Discard the oil fil- ter and O-ring. NOTE: Clean up any excess oil after removing the  filter. Thoroughly clean the oil filter mating surface on the crankcase.

  • Page 11: Front Differential/Rear Drive Lubricant

    Front Differential/Rear Drive Lubricant CAUTION Any lubricant used in place of the recommended gear lube could result in premature failure of the shock lim- iter. Do not use any lubricant containing graphite or molybdenum additives or other friction-modified lubri- cants as these may cause severe damage to shock lim- iter components.

  • Page 12: Hydraulic Brake Systems

    2. With the ignition switch in the ON position, loosen jam nut (A) (left-hand threads); then loosen jam nut (C) and with the shift lever in the reverse position, adjust the coupler (B) until the transmission is in reverse and the (R) icon appears on the LCD. CF723 2.
  • Page 13 C. Remove the protective cap, install one end of a clear hose onto the rear bleeder screw, and direct the other end into a container; then while holding slight pres- sure on the brake pedal, open the bleeder screw and watch for air bubbles.

  • Page 14: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both main and auxiliary) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
  • Page 15 CHECKING Use the 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 standard V-belt measurement is 35.0 mm.

  • Page 16: Steering/Body/Controls

    2. Unlock the storage compartment lid; then slide the storage compartment cover assembly forward and Steering/Body/Controls lift off the storage compartment. The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B.
  • Page 17 7. Remove the left and right footwells; then remove the shift knob. Remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. FI464A 5. Remove the cap screws and lock nuts securing the front rack to the frame;...
  • Page 18 4. Install the footwells and footrests. Tighten securely. 5. Install the cap screws securing the front body panel to the frame and rear panel. CD765A NOTE: It may be necessary to rotate the body panel  to the right to align the opening with the handlebar. CLEANING AND INSPECTING FI470A 6.

  • Page 19: Rear Body Panel/Rack

    CF668A FI467 2. Remove the cap screws and lock nuts securing the 9. Install the steering post cover and secure with the rear body panel to each footwell. reinstallable rivets; then install and secure the radia- tor access panel. CF669 3.

  • Page 20: Indicator Display

    3. Inspect threaded areas of all mounting bosses for stripping. Indicator Display 4. Inspect for missing decals. INSTALLING REPLACING 1. Remove the gas tank cap and set the rear body panel 1. Remove the two reinstallable rivets securing the in position; then install the cap and connect the tail- indicator display;...
  • Page 21 6. Remove the four cap screws securing the handlebar caps and indicator display bracket to the steering post; then move the handlebar and gauge out of the way. Account for four handlebar caps. FI465A 3. Remove four reinstallable rivets securing the steer- ing post cover and remove the cover.
  • Page 22 KX039 AL600D 10. Remove two cap screws securing the lower steering 2. Place the upper steering post mounting blocks into post bearing flange to the frame; then remove the position; then insert the two shoulder screws through steering post. the frame and thread them into the steering post mounting bracket.

  • Page 23: Handlebar Grip

    6. Install the storage compartment box; then attach the storage compartment cover assembly by engaging the tabs into the slots and sliding rearward. Lock the storage compartment lid to hold the assembly in place. 7. Place the instrument pod into position; then secure with two reinstallable rivets and the ignition switch retaining ring.
  • Page 24 CF725A AF678D 2. Slide the grommet out of the lower half of the throt- INSTALLING tle control; then remove the cable from the actuator 1. Place the return spring into the throttle control; then arm. place the bushing and actuator arm into position. Secure with the cap screw, lock washer, and washer.

  • Page 25: Steering Knuckles

    CF725A PR288 CAUTION ADJUSTING To adjust throttle cable free-play, see Fuel/Lubrication/ Use extreme care when removing the bearing. If the Cooling. bearing is allowed to fall, it will be damaged and will have to be replaced. CLEANING AND INSPECTING Steering Knuckles 1.

  • Page 26: Front Wheel Alignment

    3. Install the tie rod end and secure with the nut. Tighten to 30 ft-lb; then install a new cotter pin and spread the pin. NOTE: During assembling, new cotter pins should  be installed. PR264A 8. Pump the hand brake lever; then engage the brake lever lock.

  • Page 27: Shift Lever

    INSTALLING 5. Mark the center line of the front tires at the front and the rear of the tire; then using a tape measure, mea- 1. Place the spring into position between the upper shift sure and record the distance between the marks at the arm and shift lever;...

  • Page 28: Front Rack

    3. Adjust the cable. The main cable adjuster is located 2. Install the two flange bolts and lock nuts on the within the front left wheel well. Pull the rubber cover upper supports. Tighten all hardware securely. (A) away, loosen the jam nut (B), and turn the adjuster (C).

  • Page 29: Muffler

    INSTALLING 1. Place the assembly into position on the body and Muffler secure with torx-head cap screws and any washers. 2. Tighten the cap screws securely. REMOVING 3. Route the wiring harness over the rear frame; then 1. Remove the two exhaust springs at the muf- connect the three-prong connector.
  • Page 30 CF135A ATV-0070C 2. Pull the bulb straight out of the socket; then insert a  NOTE: There should be an average operating load new bulb. on the ATV when adjusting the headlight aim. 2. Measure the distance from the floor to the mid-point of each headlight.

  • Page 31: Troubleshooting

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

  • Page 32: Engine/Transmission

    Engine/Transmission Specifications NOTE: Specifications subject to change without notice.  This section has been organized into sub-sections which show a progression for the complete servicing of the VALVES AND GUIDES engine/transmission. Valve Face Diameter (max) (intake) 31.6 mm (exhaust) 27.9 mm NOTE: Use new gaskets, lock nuts, and seals and ...

  • Page 33: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Gasoline bad 1. Drain gas - replace with clean gas 2. Valve clearance out of adjustment 2. Adjust clearance 3. Valve guides worn 3.
  • Page 34 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 incorrect 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 35: Removing Engine/Transmission

    Removing Engine/Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service Top-Side Com- ponents, Left-Side Components, or Right-Side Compo- 733-441A nents, the engine/transmission does not have to be removed from the frame.
  • Page 36 10. Remove the spark plug cap from the spark plug; then 13. Disconnect the connectors from the TPS, ISC valve, disconnect the primary connector (A) from the igni- fuel injector, and MAP sensor. Loosen the intake tion coil. boot clamp; then move the throttle body out of the way.
  • Page 37 XR302 XR303 17. Remove the springs securing the muffler to the  NOTE: It is advisable to lock the brake when loos- exhaust pipe; then remove the muffler. Account for ening the cap screws securing the rear driveshaft. the two exhaust springs. 21.
  • Page 38 CF676B CF728A 24. On the right side, disconnect the stator coil and crankshaft position sensor connectors. 25. Disconnect the coolant temperature sensor connector from the sensor. 26. Remove the engine mounting through-bolts. Account for all mounting hardware. CD813 29. Remove the block from under the engine and lower the engine;...

  • Page 39: Servicing Engine

    Servicing Engine Top-Side Components ..........38 Removing Top-Side Components ....... 38 Servicing Top-Side Components ........ 41 Installing Top-Side Components ......... 47 Left-Side Components ..........51 Removing Left-Side Components....... 52 Servicing Left-Side Components ........ 54 Installing Left-Side Components......... 56 Right-Side Components ..........59 CC001D Removing Right-Side Components ......
  • Page 40 CD211A CC013D 5. Remove the cap screw on the end of the tensioner; 8. While holding the chain, slide the sprocket and cam- then remove the two cap screws securing the ten- shaft out of the cylinder head. sioner adjuster assembly and remove the assembly. NOTE: Loop the chain over the cylinder head and ...
  • Page 41 CC017D CC020D 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. CC018D 11. Remove the four cylinder head bolts. Account for the washers.

  • Page 42: Servicing Top-Side Components

    CC024D CC032D 17. Using the Piston Pin Puller, remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side  circlip prior to using the puller. CC025D CC033D NOTE: Support the connecting rod with rubber ...
  • Page 43 Cleaning/Inspecting Valve Cover 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. NOTE: If the valve cover cannot be trued, the cylin-  der head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. 2.
  • Page 44 NOTE: If the paint is not visible, install the ends of  the springs with the closest wound coils toward the head. CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. NOTE: If the existing rings will not be replaced with ...
  • Page 45 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. H1-051 2. Install the second compression ring with the marking “RN” directed toward the top of the piston. Orientate the opening of the ring at 0°...
  • Page 46 Cleaning/Inspecting Cylinder Head Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. CAUTION 2. Inspect the cylinder for pitting, scoring, scuffing, The cylinder head studs must be removed for this pro- warpage, and corrosion. If marks are found, repair cedure. the surface using a cylinder hone (see Inspecting 1.
  • Page 47 2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit ball hone. NOTE: To produce the proper 60° cross-hatch pat-  tern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute.

  • Page 48: Installing Top-Side Components

    3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings Installing Top-Side and slide the cylinder over the piston. Route the cam Components chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
  • Page 49 C. Cylinder Head D. Valve Cover NOTE: Steps 1-5 in the preceding sub-section must  precede this procedure. 6. Place the chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. CC272D 9.
  • Page 50 15. With the cam lobes directed down (toward the pis- ton), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket. NOTE: Note the position of the alignment marks on  the end of the camshaft.
  • Page 51 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 52: 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 53: Removing Left-Side Components

    4. Disconnect the harness connector (A) from the gear shift selector switch (B). Removing Left-Side Components A. Outer Magneto Cover B. Water Pump C. Cover D. Rotor/Flywheel 1. Remove the four cap screws securing the outer mag- neto cover to the left-side cover; then remove the outer magneto cover.
  • Page 54 10. Using an appropriate side case puller, remove the side cover. Account for a gasket and two alignment pins. 11. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter. NOTE: The puller has left-hand threads. ...

  • Page 55: Servicing Left-Side Components

    NOTE: There is an oil passage beneath the driven  gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. 16.
  • Page 56 FI576A FI580 INSPECTING STATOR COIL/MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws. 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores.

  • Page 57: Installing Left-Side Components

    FI595A CD949  NOTE: The sharp side of the snap ring should be facing outward. Installing Left-Side Components 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing);...
  • Page 58 CD139 PR433A H2-045 CD934 4. In order on the crankshaft, install a washer, ring gear, 6. Install the shift cam stopper, spring, and two washers key, and the magneto rotor. Secure with the nut. (thick washer closest to the nut); then coat the Tighten to 107 ft-lb.
  • Page 59 CD954A CF729A 13. 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. 14. Install the crossover tube on the water pump and cyl- inder head making sure the O-ring is properly posi- tioned.

  • Page 60: Right-Side Components

    Right-Side Components NOTE: For efficiency, it is preferable to remove and  disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary.
  • Page 61 6. Remove the fixed drive face from the drive clutch assembly. 7. Remove all cap screws securing the inner clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Five cap screws are located outside of the mating surface of the two clutch covers.
  • Page 62 CF088A CC606 9. Remove the two cap screws securing the gear posi- 12. Using an impact wrench, remove the cap screws tion switch; then remove the switch. securing the final drive carrier bearing housing (D); then remove the housing and account for two align- 10.

  • Page 63: Servicing Right-Side Components

    14. Using an impact driver, remove the three torx-head screws securing the oil pump; then remove the pump. ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. CD988 2. If the housing is damaged in any way, the housing Servicing Right-Side must be replaced.
  • Page 64 ATV1152A CF381 3. Check the internal bushing of the movable drive DRIVEN CLUTCH ASSEMBLY sheave and surface of the spacer. Replace as neces- sary. Check the fixed drive sheave internal splines Disassembling for excessive wear. Check for any broken cooling 1.
  • Page 65 WC418A WC383 4. Turn the wing nut counterclockwise to relax the 2. Inspect the cam shoes on the movable driven sheave spring. As the cam clears the key in the fixed driven for chipping, excessive scoring, or general condition. shaft, there will be a slight clockwise rotation of the cam.
  • Page 66 WC383A WC388 6. Inspect the spring for kinks by rolling on a flat sur- 3. Install the spring over the hub of the movable driven face. The spring should roll freely with no irregulari- sheave engaging the spring into the previously ties.

  • Page 67: Installing Right-Side Components

    WC414 WC412 6. Turn the wing nut clockwise to compress the spring being very careful that the cam correctly engages the fixed driven hub; then continue to tighten until the cam ramps are just above the cam shoes. WC419 9. Turn the wing nut counterclockwise slowly allowing the cam to contact the snap ring;...
  • Page 68 CD999 CD991 2. Install the oil pump onto the engine; then tighten the 4. Place the washer (A) onto the oil pump driveshaft; screws (coated with red Loctite #271) to 8.5 ft-lb. then grease the driven gear pin (B) and insert it into the oil pump driveshaft.
  • Page 69 H1-029C CF085A 8. Apply grease to the outer edges of the clutch hous- ing; then from inside the clutch cover, install the clutch housing into the cover using a rubber mallet. 9. Place the clutch cover/housing assembly into posi- tion on the crankcase; then secure with the cap screws making sure the different-lengthed cap screws are in their proper location.

  • Page 70: Center Crankcase Components

    H1-020A CF379 13. Place the V-belt into position on the driven pulley  NOTE: At this point, the cap screw can be removed and over the front shaft. from between the driven pulley faces. 15. With the vehicle in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush with the top of the driven pulley.

  • Page 71: Disassembling Crankcase Half

    2. Remove the left-side cap screws securing the crank- case halves. Note the location of the differ- ent-lengthed cap screws. 3. Using the Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins. NOTE: To keep the shaft/gear assemblies intact for ...
  • Page 72 CC674 CD832B 9. Remove the snap ring securing the water pump NOTE: Do not disassemble the countershaft assem-  driven gear shaft. bly unless necessary. If necessary, see Servicing Cen- ter Crankcase Components sub-section. 10. Using a hydraulic press, remove the crankshaft assembly.

  • Page 73: Servicing Center Crankcase Components

    Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up  NOTE: If the secondary output driven shaft is replaced or disassembled, the initial set-up must be performed to establish correct gear tooth contact. If only the secondary output driveshaft or secondary output driven gear is replaced, proceed to Correcting MT012 Backlash in this sub-section.

  • Page 74: Crankshaft Assembly

    NOTE: Continue to remove, measure, and install  until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Shim Correction Under 0.127 mm (0.005 in.) Decrease Shim Thickness At 0.127-0.381 mm (0.005-0.015 in.) No Correction Required Over 0.381 mm (0.015 in.) Increase Shim Thickness After backlash and tooth contact are within specifications, apply red Loctite #271 to the driveshaft threads and driven...
  • Page 75 2. Acceptable width range must not exceed specifica- tions. COUNTERSHAFT CC289D 3. Acceptable gap range must not exceed specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. GZ281A CAUTION 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- When disassembling the countershaft, care must be shaft.
  • Page 76 GZ296 H1-045A H1-043 H1-046A 4. Remove the reverse driven gear dog. 6. Remove the reverse driven washer (D); then remove the low driven gear (E). GZ313A 5. Remove the snap ring securing the reverse driven H1-047A gear and washer; then remove the washer (A), 7.
  • Page 77 Assembling 3. Install the outer reverse driven gear washer (A); then secure the reverse driven gear assembly with a new 1. From the drive gear end, install a thrust washer, and snap ring. bearing; then install the low driven gear and washer. H1-045A H1-049A H1-044...

  • Page 78: Assembling Crankcase Half

    6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bearing (C), high driven gear (D), and spacer washer (E). CC689 NOTE: If heating the bearing is not possible, the  crankshaft can be installed using a crankshaft install- ing tool.

  • Page 79: Joining Crankcase Halves

    CC675 CC669 6. Place a washer on each end of the countershaft 9. Install the reverse idler gear assembly noting the assembly; then install the assembly. positioning of the two washers, gear, bushing, and shaft. CC674 7. Place a washer on the end of the gear shift shaft; then CC668 install the shaft assembly making sure the two holes 10.

  • Page 80: Installing Engine/Transmission

    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 81 XR299A CD809 6. Using a new exhaust gasket, secure the exhaust pipe to the engine with two cap screws; then install the muffler making sure the mounting brackets engage the frame grommets. Tighten the cap screws securing the exhaust pipe to the cylinder head to 20 ft-lb. Con- nect the O2 sensor.
  • Page 82 CF684A CF731A 17. Connect the fuel hose connector to the fuel rail. CD786 20. Connect the intake air temperature sensor connector. CF730A 18. Connect the connectors from the TPS, ISC valve, fuel injector, and MAP sensor. CD674 21. Connect the primary connector (A) to the ignition coil;...
  • Page 83 26. Install the side panels into position. 27. Place the battery into position in the battery compart- ment; then install the battery cables (positive cable first). Secure with the battery cover. CAUTION Battery acid is harmful if it contacts eyes, skin, or cloth- ing.

  • Page 84: Fuel/Lubrication/Cooling

    3. Remove the storage compartment cover and storage compartment. Remove the air filter housing cover; Fuel/Lubrication/ then remove the air filter. Account for the air filter Cooling frame.  NOTE: Use new gaskets, lock nuts, and seals and lubricate all internal components when servicing the engine/transmission.
  • Page 85 CF688 CF733A 5. Slowly disconnect the fuel hose connector from the 10. Loosen the clamp securing the throttle body to the fuel rail. intake manifold flange. Remove the throttle body. ! WARNING Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting.

  • Page 86: Throttle Cable Free-Play

    4. Connect the four electrical connectors to the throttle 2. Remove the rear rack and fenders (see Steer- body components. ing/Body/Controls). 5. Install the intake pipe that joins the air filter housing to 3. Using an absorbent towel under the hose, disconnect the throttle body boot and secure with the clamps.

  • Page 87: Oil Flow Chart

    TESTING OIL PUMP PRESSURE  NOTE: Some oil seepage may occur when installing  NOTE: The engine must be warmed up to the speci- the oil pressure gauge. Wipe up oil residue with a fied temperature for this test. cloth. 1.

  • Page 88: Liquid Cooling System

    CAUTION Liquid Cooling System After operating the ATV for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary. When filling the cooling system, use a coolant/water RADIATOR mixture which will satisfy the coldest anticipated weather conditions of the area in accordance with the coolant Removing...

  • Page 89: Water Pump

    Installing B. Heat the water and monitor the temperature with a thermometer. 1. Position the fan/fan shroud assembly on the radiator; then secure with existing hardware. C. The thermostat should start to open at 146-151°F. 2. Place the radiator with grommets and collars into D.

  • Page 90: Troubleshooting

    5. Remove the two cap screws securing the water pump 3. Place the footrest into position on the frame and to the engine; then remove the water pump. loosely secure with four cap screws; then secure the front and rear fenders to the footrest with the four torx-head cap screws.

  • Page 91: Electrical System

    Maintenance Charging Electrical System  NOTE: Use the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two weeks or as required by bat- The electrical connections should be checked periodi- tery drain.

  • Page 92: Ignition Switch

    3300A CF724A  NOTE: Not using a battery charger with the proper float maintenance will damage the battery if con- nected over extended periods. Charging NOTE: Use the CTEK Multi US 800 or the CTEK  Multi US 3300 for battery maintenance charging. 1.

  • Page 93: Ignition Coil

    5. Turn the ignition switch to the LIGHTS position. NOTE: Secondary coil resistance checks are not rec-  ommended. An internal diode in the coil prevents 6. Connect either tester lead to pin A; then connect the accurate secondary resistance measurements. other tester lead to pin D.
  • Page 94 VOLTAGE (Brakelight) Auxiliary 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester to the orange wire; then con- nect the black tester lead to the red/blue wire. Auxiliary FI502 Handlebar FI510 Handlebar FI490 3. When the brake pedal/lever is depressed, the meter must show less than 1 ohm.

  • Page 95: Fan Motor

    RESISTANCE (Gear Position) 1. Set the meter selector to the Diode position. 2. Connect the red tester lead to the orange/white wire; then connect the black tester lead to the yellow/green wire. 3. With the starter button depressed, the meter must Component data can be retrieved using the CATT II.

  • Page 96: Lights

    NOTE: To determine if the fan motor is good, con- 1. Set the meter selector to the DC Voltage position.  nect the red wire from the fan connector to the posi- 2. Connect the red tester lead to the red/blue wire; then tive side of a 12 volt battery;...

  • Page 97: Efi Sensors/Components

    NOTE: The battery must be at full charge for the  voltage test. 2. Set the meter selector to the AC Voltage position. 3. Connect the red tester lead to the blue wire; then con- nect the black tester lead to the green wire. 4.
  • Page 98 ENGINE COOLANT TEMPERATURE 4. Connect the MAP sensor to the harness; then using MaxiClips, connect the red tester lead to the (ECT) SENSOR brown/white wire and the black tester lead to the black/pink wire. With the engine running at idle speed, the meter should read approximately 2.5 DC volts (MAP sensor signal).
  • Page 99 INSPECTING 1. Turn the ignition switch ON and listen for a momen- tary “whirring” sound of the pump building pressure. AT THIS POINT  If the sound is heard (10 seconds), no electrical checks are necessary. Turn the ignition switch OFF. If the pump has failed earlier test and must be replaced, proceed to INSTALLING.

  • Page 100: Tilt Sensor

    3. Rotate the fuel pump until the match marks align; then install the mounting screws and tighten securely using a crisscross pattern. NOTE: It is critical to install the fuel pump with the  correct orientation to ensure adequate float lever clearance.
  • Page 101 CD706B CD709  NOTE: When replacing the sensor after testing, Output Voltage make sure the arrow marking is directed up. NOTE: Needle adapters, Maxi-Clips  “break-out” harness will be required on the multime- ter leads as the following tests are made with the sen- sor connected.
  • Page 102 4. Connect the black test lead to the (VAR) and the red test lead into the (+5V) sockets on the analyzer. Select the DC Voltage position on the multimeter. With the vehicle off and the throttle plate fully closed, the gauge should read 0.58-0.62 DC volts and at Wide-Open Throttle it should read up to approximately 3.7 DC volts.

  • Page 103: Rpm Limiter

    RPM Limiter Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen. NOTE: The ATV is equipped with an ECM that cuts fuel spray and spark when maximum RPM is approached.  When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire. Gear Park Neutral...

  • Page 104: Starter Motor

    INSTALLING 1. Apply a small amount of grease to the O-ring seal on Starter Motor the starter motor; then install the starter motor into the crankcase. Secure with two machine screws and wiring forms. NOTE: The starter motor is a non-serviceable com- ...

  • Page 105: Electronic Control Module (Ecm)

    5. Depress the starter button and observe the multimeter. NOTE: If battery voltage is indicated, replace the  starter relay. If no voltage is indicated, proceed to Power Distribution Module (PDM) check in this section. Electronic Control Module (ECM) The electronic control module (ECM) is located beneath the seat near the battery.

  • Page 106: Efi Diagnostic System

    DIAGNOSTIC TROUBLE CODES (DTC) The High Temperature Indicator Light illuminates (con- tinuously ON) when the engine has reached a tempera- If an EFI or related chassis component fails or an ture of 230°F (110°C). This light will not be visible out-of-tolerance signal is detected by the ECM, a diag- during normal operation.
  • Page 107 Code Fault Description Possible Cause Fault Recovery Method P0485 Fan-Primary/Right Relay Control Circuit Primary fan fuse has blown, the primary fan relay has been removed Correct condition* Low/SG/Open or interconnect harness shorted to chassis ground P0500 Vehicle Speed-Sensor Sensor circuit signal intermittent or missing Correct condition*, start and drive the vehicle* P0508...

  • Page 108: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace stator coil 4. ECM defective 4. Replace ECM 5. Pick-up coil defective 5.

  • Page 109: Drive System/Brake System

    Drive System/Brake System GENERAL INFORMATION 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; then use the following torque values. Size New Housing Reassembled Housing ATV0082A M6 (Torx T-30 Recess) 8-9.5 ft-lb 6.5-9 ft-lb...
  • Page 110 12. Support the axle to not allow it to drop or hang. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. 13. Remove the lower shock bolts. Account for the lock nuts;...
  • Page 111 16. Loosen the two jam nuts (A) securing the four wheel drive selector cable housing to the bracket. Remove the four wheel drive tensioner spring (B) from the selector shaft (C). NOTE: Record the set length of the four wheel drive ...
  • Page 112 XR348 GC011 3. Using a boot-clamp pliers (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the snap ring; then remove the input shaft from the pinion housing. XR350 XR349 5.
  • Page 113 GC011 XR352A 2. Install the input shaft seal making sure it is fully seated in the housing. XR354 5. Place the dowel pin into the differential housing; then install a new gasket. Place the coupler onto the GC014 shift fork; then simultaneously engage the shift fork 3.
  • Page 114 XR347 XR352A 7. Install the input shaft into the pinion housing; then 2. Using a T-40 torx wrench, remove the cap screws install the front boot and secure with the appropriate securing the differential cover. boot clamps and then the rear boot. 3.
  • Page 115 3. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press. Account for a collar and a bearing. XR358 CC879 4. Remove any reusable parts from the gear case hous- ing; then discard the housing and lock collar. Assembling Pinion Gear 1.
  • Page 116 Backlash  NOTE: Always set backlash prior to any other shimming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly. CC884 3. Using a propane torch, heat the gear case housing to approximately 200°...
  • Page 117 GC040 GC035 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.  NOTE: Once proper backlash and end play are established, the gear case can be assembled (see Assembling Differential Assembly in this sub-section).
  • Page 118 6. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket. GC036B NOTE: The spider and ring gear assembly must be  replaced as a complete unit. XR353 3.
  • Page 119 GC060 CF737A 5. Pull the rubber seal off the end of the cable housing CAUTION then un-thread the very next jam nut off the end of Make sure the tool is free of nicks or sharp edges or the cable housing. Slide the cable through the slot on top of the bracket then insert the threaded section of damage to the seal may occur.

  • Page 120: Drive Axles

    11. Install the wheel; then 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). 12. Check the front differential for normal 2WD/4WD operation.
  • Page 121 NOTE: Do not allow the brake calipers to hang  from their cable/hose. CAUTION The calipers should be supported. If the calipers are allowed to hang from the cable/hose, damage may occur. 6. Slide the hub out of the knuckle and set aside. 7.
  • Page 122 CF637 CF633A NOTE: Steps 1-3 can be used to replace the out-   NOTE: To assure proper seating of the axle, give it a board boot. light pull; the axle should remain “clipped” in place. ASSEMBLING AXLES 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm.

  • Page 123: Rear Gear Case

    INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steering knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tight- ened to 50 ft-lb. 2. Place the brake hose into position on the upper A-arm;...

  • Page 124: Hub

    XR435A GC058A 3. If clearance is as specified, remove the ring gear and AT THIS POINT  thrust button; then place a drop of red Loctite #271 For servicing the input shaft, pinion gear, needle bear- on the threads and tighten to 8 ft-lb (left-hand ing, ring gear, and axle seal, see Front Differential in threads).

  • Page 125: Hand Brake Lever/Master Cylinder Assembly

    XR263A XR263A 6. Using an appropriate hub retaining wrench, tighten NOTE: Do not allow the brake calipers to hang  the hub nut (from step 4) to 200 ft-lb; then install and from their cable/hose. spread a new cotter pin making sure each side of the pin is flush to the hex nut.
  • Page 126 AF637D DE058A 2. Place an absorbent towel around the connection to INSPECTING absorb brake fluid. Remove the banjo-fitting from 1. Inspect the pin securing the brake lever for wear. the master cylinder. Account for two crush washers and a banjo-fitting bolt. 2.

  • Page 127: Hydraulic Brake Caliper

    DE059A PR235 3. Gently press the brakelight switch into the housing CAUTION (left to right) until the mounting tabs snap into the four locating holes; then install the brake lever, pivot Brake fluid is highly corrosive. Do not spill brake fluid pin, and snap ring.
  • Page 128 CLEANING AND INSPECTING 5. Remove the caliper holder from the caliper and dis- card the O-ring. 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2. Inspect the brake pads for damage and excessive wear.
  • Page 129 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads.

  • Page 130: Troubleshooting Drive System

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

  • Page 131: Suspension

    CAUTION Suspension Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur. The following suspension system components should be 3. Remove the two cap screws and nut securing each inspected periodically to ensure proper operation. rear shock absorber to the frame and lower A-arm.

  • Page 132: Front A-Arms

    Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the cotter pin from the nut. Discard the cot- XR367 ter pin.
  • Page 133 XR368 CF661 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount; then secure the hose to the A-arm 1. Clean all A-arm components using a pressure with a brake hose clip and grommet. washer. 2.

  • Page 134: Rear A-Arms

    3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock. 5. Remove the caliper (right side only).  NOTE: Do not allow the brake caliper to hang from the cable/hose.

  • Page 135: Wheels And Tires

    11. Secure the boot guard to the lower A-arm with the two cap screws. Tighten securely. 12. Install the wheel; then using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/chrome nuts).

  • Page 136: Troubleshooting

    Install each wheel on its hub ; then using a crisscross pat- 2. Inspect the tires for damage, wear, or punctures. tern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel ! WARNING w/black nuts), or 80 ft-lb (aluminum wheel w/chrome Do not operate the ATV if tire damage exists.
  • Page 137 NOTES...
  • Page 138 ©2017 Arctic Cat Inc. Effective: May 2017 Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2261-427...

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