Arctic Cat Altera 300 Service Manual
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Arctic Cat Altera 300 Service Manual

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2017
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ERVICE
ERVICE
www.arcticcat.com
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ANUAL
ANUAL

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

  • Page 2: Table Of Contents

    2017 Alterra 300 Service Manual Table Of Contents General Information/Foreword.......... 2 Fuel/Lubrication/Cooling ..........63 Specification ..............2 Carburetor ..............63 Torque Specifications............ 3 Throttle Cable Free-Play ..........66 Torque Conversions (ft-lb/N-m)........4 Engine RPM (Idle) ............67 Gasoline - Oil - Lubricant..........4 Gas Tank ..............67 Preparation For Storage ..........

  • Page 3: General Information/Foreword

    Taillight/Brakelight 12V/5W/21W When replacement of parts is necessary, use only genuine Headlight 12V/35W (2) Arctic Cat ATV parts. They are precision-made to ensure FUEL SYSTEM high quality and correct fit. Refer to the appropriate Illus- Carburetor Type Keihin CVK32 trated Parts Manual for the correct part number, quantity, Main Jet and description.

  • Page 4: Torque Specifications

    CYLINDER, PISTON, AND RINGS BRAKE COMPONENTS Piston Skirt/Cylinder Clearance (max) 0.12 mm Torque Part Part Bolted To Cylinder Bore 72.705-72.715 mm ft-lb N-m Piston Diameter 18 mm from Skirt End 72.625 mm Brake Hose Union Bolt Master Cylinder/ (max) Caliper Bore x Stroke 72.7 x 65.2 mm Brake Bleed Screw...

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

    35.4 69.4 103.4 36.7 70.7 104.7 CAUTION 38.1 72.1 106.1 Do not use white gas. Only Arctic Cat approved gaso- 39.4 73.4 107.4 line additives should be used. 40.8 74.8 108.8 RECOMMENDED ENGINE OIL 42.2 76.2 110.2...

  • Page 6: Preparation For Storage

    Taking the ATV out of storage and correctly preparing it CAUTION will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to pre- Prior to storing the ATV, it must be properly serviced to pare the ATV.

  • Page 7: Periodic Maintenance/Tune-Up

    NOTE: Foam Filter Cleaner and Foam Air Filter  CLEANING AND INSPECTING FILTER Oil Aerosol are available from Arctic Cat. CAUTION 5. In a pan larger than each element, with a mild deter- Failure to inspect the air filter frequently if the vehicle is...

  • Page 8: Valve/Tappet Clearance

    7. Remove any excess water from the elements by mat- NOTE: At this point, the round hole in the camshaft  ting with a towel; then allow the elements to dry gear should be up. completely. 3. Place Tappet Adjuster onto the jam nut securing the tappet adjuster screw;...

  • Page 9: Spark Plug

    NOTE: The engine must be warm and the battery  must be fully charged for this test. 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).

  • Page 10: Engine Oil - Filter

    4. Remove the screen/filter cap from the bottom of the engine and drain the oil into a drain pan. Account for a spring, O-ring, and screen/filter. Discard the O-ring. ! WARNING Use extreme caution when removing the oil drain plug. Hot oil can cause severe injury and skin burns.

  • Page 11: Rear Drive Lubricant

    11. Inspect the area around the screen/filter cap for leaks. 1. Place the ATV on level ground. 2. Loosen the fill plug; then remove the transmission drain plug and drain the transmission lubricant. Rear Drive Lubricant Check and change the lubricant according to the Periodic Maintenance Chart.

  • Page 12: Shift Lever

    Shift Lever Hydraulic Brake Systems CHECKING FLUID/BLEEDING The hydraulic brake systems have been filled and bled at the factory. 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the res- ervoir is not visible in the sight glass, add DOT 4 brake fluid.
  • Page 13 D. At this point, perform steps B and C on the FRONT RIGHT bleed screw; then move to the FRONT LEFT bleed screw and follow the same procedure. 4. Carefully check the entire hydraulic brake system that all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present.
  • Page 14 KM267 KM266A Inspecting and Measuring 5. Install the wheel. Tighten in a crisscross pattern to 40 ft-lb. 1. Inspect the pads for gouges, chips, or wear. 6. Burnish the brake pads (see Burnishing Brake Pads 2. Inspect the disc for gouges, grooves, cracks, and in this section).

  • Page 15: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both hydraulic and auxiliary) must be bur- nished to achieve full braking effectiveness. Braking dis- tance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
  • Page 16 2. Install the centrifugal clutch housing onto the driven shaft; then install the splined bushing and secure with the driven pulley retaining nut. Tighten to 40 ft-lb. KM263A CAUTION If the splines are not protruding as shown, the V-belt may be too deep in the drive sheaves. This would cause KM276 the drive pulley to be under-tightened and severe drive 3.

  • Page 17: Steering/Body/Controls

    Steering/Body/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent or cracked and has equal and complete full-left and full-right turning capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.
  • Page 18 8. Remove the two self-tapping screws securing the inlet of the CVT intake tube to the front body panel. XA069 6. Remove the Phillips-head screws with lock nuts and three cap screws securing each footwell to the vehi- XA067 cle. Remove the footwells. 9.

  • Page 19: Front Fascia/Headlight

    CLEANING AND INSPECTING 1. Clean all body components with soap and water. 2. Inspect the body and fenders for cracks. 3. Inspect threaded areas of all mounting studs for strip- ping. 4. Inspect for missing decals. INSTALLING 1. Place the front panel assembly onto the frame. Loosely install the four cap screws located under the seat.
  • Page 20 XA072 XA083A 2. Remove the cap screws securing each headlight CLEANING AND INSPECTING assembly to the front fascia and front body panel. 1. Clean the fascia and related components with soap Remove the headlights. and water. 2. Inspect the fascia and fenders for cracks. 3.

  • Page 21: Rear Rack/Body Panel/Fender

    XA072 XA077A 4. Remove the self-tapping screws securing the rear over-mold to the rear rack; then remove the four cap Rear Rack/Body screws securing the rear rack to the frame. Remove the rack. Account for the four steel inserts installed Panel/Fender into each rubber grommet.
  • Page 22 6. Using a flat blade screwdriver, release the connector locking tabs; then disconnect the tail light/brakelight connectors. XA080A 4. Install the six cap screws securing the front body panel to the frame, gas tank, and rear body panel; then install and secure the gas tank cover and steer- XA084A ing post covers using the plastic reinstallable rivets.

  • Page 23: Steering Post Cover/Instrument Pod

    Steering Post/Tie Rods REMOVING 1. Remove the steering post cover. 2. Remove the instrument pod; then remove the cap screws securing the handlebar to the steering post. Account for two handlebar holders. XA085A XA075A 3. Lift the handlebar out of the lower handlebar holders and lay the handlebar forward.
  • Page 24 KM589 KM589 6. Remove the steering post from the ATV. CLEANING AND INSPECTING 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. ! WARNING Always wear safety glasses when using compressed air.

  • Page 25: Front Wheel Alignment

    5. Install the handlebar and tighten the clamp cap 4. Adjust toe-in to 15 mm (0.60 in.); then measure dis- screws to 18 ft-lb making sure to tighten the front tances (C) and (D). Distances (C) and (D) should be cap screws first.

  • Page 26: Headlight - Taillight/Brakelight

    Headlight - Taillight/Brakelight Turn the ignition switch to the LIGHTS position; the headlights and taillight should illuminate. Test the brake- light by compressing the brake lever. The brakelight should illuminate.  NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE.

  • Page 27: Troubleshooting

    3. Install the new bulb by turning it clockwise while pushing in. Troubleshooting 4. Insert the socket into the taillight housing; then rotate the socket clockwise to secure. Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1.

  • Page 28: Engine/Transmission

    Spanner Wrench 0444-192 from the frame. Flywheel Holder 0444-193 NOTE: Arctic Cat recommends the use of new gas-  Magneto Rotor Remover 0444-187 kets, lock nuts, and seals and lubricating all internal Tappet Adjuster 0444-189 components when servicing the engine/transmission.

  • Page 29: 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 - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 30 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 31 Problem: Engine overheats Condition Remedy 1. Carbon deposit (piston crown) excessive 1. Clean piston 2. Oil low 2. Add oil 3. Octane low - gasoline poor 3. Drain - replace gasoline 4. Oil pump defective 4. Replace pump 5. Oil circuit obstructed 5.

  • Page 32: Removing Engine/Transmission

    7. Remove the carburetor (see Fuel/Lubrication/Cool- ing). Removing Engine/ 8. Remove the ignition coil (see Electrical System). Transmission 9. From the right side of the frame, disconnect the sta- tor connector, gear position connector, trigger coil Many service procedures can be performed without connector, and coolant temperature sensor.
  • Page 33 15. Attach a suitable lifting sling and engine lift to the front engine mounting boss; then using an engine lift, apply slight upward pressure engine/transmission. KM323 KM332A 16. Remove the upper rear and lower rear engine through-bolts to free the engine/transmission; then raise the front of the engine/transmission sufficiently to allow the engine assembly to be moved forward enough to disengage the driveshaft.

  • Page 34: Top-Side Components

    KM329 KM941A 2. Remove the vent hose from the top of the cylinder head cover. Retain the hose clamp. 3. Remove the cap screws and nuts securing the air pipe to the cylinder head cover. KM331 Top-Side Components KM937A NOTE: For efficiency, it is preferable to remove and ...
  • Page 35 NOTE: Keep the mounting hardware with the cover  for assembly purposes. 5. Remove the plug from the cam chain tensioner; then turn the cam chain tensioner screw clockwise to release the chain tension. KM718A 9. Remove the cam chain guide; then disconnect the coolant hose and remove the cylinder.

  • Page 36: Servicing Top-Side Components

    KM451 KM708A 11. Using Piston Pin Puller, remove the piston pin. 2. Inspect the camshaft holder for cracks, distortion, or Account for the opposite-side circlip. Remove the galling. piston. 3. Inspect the rocker arm shafts for blue discoloration NOTE: It is advisable to remove the opposite-side or scoring.

  • Page 37: Cylinder Head Assembly

    Measuring Valve Stem/Valve Guide Clearance 1. Using a micrometer, measure the valve stem outside diameter; then using a suitable snap gauge and micrometer, measure the valve guide inside diameter. 2. Acceptable clearance must be within specifications. Inspecting Valve Face Inspect the valve face for pitting, grooving, or discolor- ation.
  • Page 38 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must not exceed speci- fications. KM717A PISTON ASSEMBLY NOTE: Whenever a piston, rings, or pin are out of  KM452 tolerance, they must be replaced. Measuring Piston Pin (Outside Inspecting Piston Diameter) and Piston-Pin Bore 1.

  • Page 39: Cylinder Assembly

    Measuring Piston Skirt/ Cylinder Clearance 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 40: Installing Top-Side Components

    C. Cylinder Head D. Valve Cover NOTE: Steps 1-4 in the preceding sub-section must  precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 41 11. Install the cam chain tensioner cover bolt and tighten to 24 in.-lb. 12. Check that the cam gear alignment marks are cor- rectly oriented; then install and tighten the external cylinder head to cylinder cap screws to 7 ft-lb. 13.

  • Page 42: Left-Side Components

    KM253 KM941A 3. Using a suitable holder to prevent the drive pulley from turning, remove the drive face nut and starter ratchet; then remove the drive pulley face. Left-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.

  • Page 43: Servicing Left-Side Components

    KM369 KM411 6. Remove the drive pulley collar and the movable 4. Carefully lift the reel free of the case making sure the drive face taking care not to loose the rollers. spiral spring does not accidentally disengage from the case. Servicing Left-Side Components RECOIL STARTER...
  • Page 44 7. Unwind the rope from the reel and remove the rope. Cleaning and Inspecting 1. Clean all components. 2. Inspect the springs and ratchet for wear or damage. 3. Inspect the reel and case for cracks or damage. 4. Inspect the shaft for wear, cracks, or damage. 5.

  • Page 45: Drive Pulley

    8. Hold the ratchet guide down in place on the ratchet pins and secure with the cap screw coated with blue Loctite #243. Tighten securely. KM254 2. Inspect the V-belt cover for cracks, distortion, and loose alignment pins. NOTE: If the V-belt cover is cracked or distorted or ...
  • Page 46 KM389 KM375 4. Remove the spring and spring seat; then remove the DRIVEN PULLEY/CENTRIFUGAL hub collar. CLUTCH ASSEMBLY Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Place the driven pulley on a suitable spring compres- sor;...
  • Page 47 Inspecting 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking. 1. Inspect the pulley faces for wear, galling, or groov- ing. KM379 5. Measure the driven face spring free length. If the free KM394A length is less than 131 mm, the spring must be 2.
  • Page 48 KX571 KM385 2. Apply multi-purpose grease to the O-rings and 5. Place the spring holder on the spring; then install the grease seals on the movable face; then install on the spring on the pulley assembly. fixed face making sure the alignment marks are properly aligned.

  • Page 49: Installing Left-Side Components

    Installing Left-Side Components A. Drive Pulley B. Driven Pulley/Centrifugal Clutch Assembly C. V-Belt Cover 1. Install the movable drive face and drive pulley collar on the crankshaft. 2. Open the faces of the driven pulley; then insert a KM263A suitable wedge between the faces to hold them apart. 5.

  • Page 50: Right-Side Components

    KM368 KM954B 7. Install the alignment pins and a new gasket on the  NOTE: If the engine has not been removed, remove crankcase; then install the V-belt cover and secure the swing arm assembly (see Drive System - Rear with the cap screws.
  • Page 51 KM649 KM652A 5. Using a Spanner Wrench to hold the centrifugal 7. Remove the shift shaft; then remove plug, clutch housing, remove the nut securing the second- seal/washer, spring, and shift cam stopper ball. ary drive bevel gear to the driveshaft. KM677A KM650 NOTE: If the engine has been removed and the...
  • Page 52 KM680 KM685 10. Remove the countershaft and driveshaft as an assem- 12. To disassemble the driveshaft, use the following pro- bly. cedure. A. Remove the thrust washer; then remove the reverse gear. KM681 11. To disassemble the countershaft, use the following procedure.
  • Page 53 14. Remove the right crankcase cover (see Fuel/Lubrica- tion/Cooling - Water Pump). 15. Remove the trigger coil mounting screws; then remove the wire set plate. KM692A 13. To disassemble the secondary driven bevel gear assembly, use the following procedure. A. Secure the universal joint using a suitable vise; then engage the output end of the shaft with the universal joint.

  • Page 54: Servicing Right-Side Components

    21. Remove the two cap screws securing the oil baffle to the crankcase and remove the baffle; then remove the snap ring securing the oil pump driven sprocket. KM766A  NOTE: The starter one-way clutch bearing is direc- tion oriented and will only function if installed prop- erly.
  • Page 55 3. Inspect the shift cam groove and shift cam gear for 10. Inspect the secondary driven bevel gear housing for excessive wear. cracks, loose bearings, or signs of discoloration from heat. Replace as required. 11. Inspect the driven shaft for scoring, discoloration, or worn splines.
  • Page 56 2. Clean the secondary driven bevel gear teeth of old oil NOTE: To correct tooth contact, increase or  and grease residue. decrease shims as necessary on both secondary drive and driven gears equally. Use the “Tooth Con- 3. Apply a thin, even coat of a machinist-layout dye to tact/Shim Correction”...
  • Page 57 4. Install the flat thrust washer and driven bevel gear on the driven shaft; then using the universal joint and vise to hold the shaft, install a new nut and tighten to 72 ft-lb. KM684 8. Install the low driven gear washer on the driveshaft; then install the low driven gear and thrust washer.
  • Page 58 KM699 KM702A 11. Install the low/reverse shift fork into the low/reverse 15. Install the two alignment pins, gasket, and transmis- clutch dog; then install the shift cam into the trans- sion case cover and secure with eight cap screws. mission case and engage the shift fork pawl in the Tighten in a crisscross pattern to 20 ft-lb.

  • Page 59: Installing Right-Side Components

    B. Rotor/Flywheel C. Trigger Coil D. Stator Coil 4. Install the starter idler shaft and gear in the crank- case; then install the starter driven gear on the crank- shaft. KM673 19. Loosely secure the secondary driven bevel gear assembly using the four cap screws; then using a crisscross pattern, tighten the cap screws until fully seated in the transmission housing.

  • Page 60: Center Crankcase Components

    2. Remove the balancer shaft from the left crankcase half. Center Crankcase Components NOTE: This procedure cannot be done with the  engine/transmission in the frame. Complete Remov- procedures Top-Side, Left-Side, Right-Side must precede this procedure.  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.

  • Page 61: Assembling Crankcase Half

    Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. ATV-1017 2. Acceptable width range must be within specifica- tions.

  • Page 62: Joining Crankcase Halves

    Joining Crankcase Halves Installing Engine/Transmission 1. Verify that the alignment pins and a new gasket are in place and that both case halves are clean and 1. Attach a suitable engine lift to the front engine grease free. Place the right-side half onto the mounting boss;...
  • Page 63 5. Install the front engine through-bolt; then tighten the engine mounting brackets to 16 ft-lb. KM319A 11. Connect the coolant temperature sensor; then con- nect the trigger coil connector, shift position connec- KM414A tor, and stator connector. 6. Tighten the nuts on the two rear and one front through-bolt to 29 ft-lb.

  • Page 64: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling Carburetor ! WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leak- KC0018 age, there should be no welding, smoking, open flames, 5. Remove the screw securing the throttle actuator etc., in the area.
  • Page 65 8. Disconnect the vent hose; then remove the carbure- tor. DISASSEMBLING 1. Remove the four Phillips-head screws securing the top cover; then remove the cover. KC0063A 4. Remove the float pin. KC0019A 2. Remove the vacuum piston assembly from the carbu- retor body.
  • Page 66 6. Secure the needle jet holder with a wrench; then remove the main jet. CC761B 1. Install the slow jet. Tighten securely. 2. Install the main jet into the needle jet holder and KC0030A 7. Remove the needle jet holder; then remove the nee- tighten securely;...

  • Page 67: Throttle Cable Free-Play

    KC0022A PR162C 5. Place the jet needle, spring seat, and spring into the 4. Place the throttle actuator cover into position on the vacuum piston; then place the assembly down into carburetor; then secure with the screw. the carburetor. 6. Place the top cover into position; then secure with the Phillips-head screws.

  • Page 68: Engine Rpm (Idle)

    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. Turn the gas tank valve to the OFF position. XA087A 2.

  • Page 69: Gas Tank Valve

    In the OFF position, the valve will not allow gasoline to flow to the carburetor. In the ON position (the normal operating position), gasoline will flow from the tank to the carburetor. In this position, 4.54 L (1.2 U.S. gal.) will remain in the tank as a reserve quantity.

  • Page 70: Liquid Cooling System

    2. Remove the Phillips-head screw on the back side of the pump and separate the pump housing and cover. Radiator Note the position of the inner and outer rotors and alignment pin for assembly. 3. Remove oil pump components. REMOVING CLEANING AND INSPECTING 1.

  • Page 71: Hoses/Thermostat

    7. Start the engine and run for 3-5 minutes; then check 3. Inspect all coolant hoses, connections, and clamps coolant level in the radiator and in the coolant over- for deterioration, cracks, and wear. flow tank and add as required to the appropriate lev- INSTALLING els.

  • Page 72: Troubleshooting

    3. Install the impeller with seal washer onto the water NOTE: While the cooling system is being filled, air  pump shaft and tighten securely. pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, 4.

  • Page 73: Electrical System

    Charging/Maintenance Charging Electrical System NOTE: Arctic Cat recommends the use of the  CTEK Multi US 800 for charging or the CTEK Multi US 3300 for battery maintenance charging. Mainte- nance charging is required on all batteries not used This section has been organized into sub-sections which...

  • Page 74: Ignition Switch

    NOTE: If, after charging, the battery does not per- lead to ground. form to operator expectations, bring the battery to an 2. The meter reading must be within specification. authorized Arctic Cat dealer for further troubleshoot- ing. NOTE: If the meter does not show as specified, ...

  • Page 75: Ignition Timing

    2. Connect the red tester lead to the brown/blue wire; then connect the black tester lead to ground. Ignition Timing 3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, trou-  The ignition timing cannot be adjusted; however, verify- bleshoot the battery, fuse, switch, or the main wiring ing ignition timing can aid in troubleshooting other com- harness.

  • Page 76: Fan Motor

    4. With the starter button released, the meter must show NOTE: Perform this test in turn on the main har-  an open circuit. ness side of the connectors. Also, the ignition switch must be in the LIGHTS position and the engine must NOTE: If the meter does not show as specified, ...

  • Page 77: Magneto Coils

    TESTING 1. Start the engine and warm up to normal operating Magneto Coils temperature; then connect a multimeter to the battery as follows. VOLTAGE (Stator Coil - Output) 2. Select the DC Voltage position; then connect the red tester lead to the positive battery post and the black NOTE: This test should be completed with a fully ...

  • Page 78: Start-In-Gear Relay

    3. On the cooling fan switch when the temperature reaches 86-90° C (187-194° F), the meter should read a closed circuit. On the coolant temperature sen- sor when the temperature reaches 120° C (218° F), the meter should read 16.0 ohms. 4.

  • Page 79: Fuse Block

    4. With the ignition switch in the ON position, select 5. The meter must show battery voltage from one side the DC volts position on the tester; then apply either of the connector terminal ends. brake. The meter must read battery voltage. If battery 6.

  • Page 80: Cdi Unit

    3. Connect the red MaxiClip to the light green/red wire; 10. Connect the red MaxiClip to the brown/black wire. then connect the jumper between the MaxiClips and The tester must read battery voltage and the speed- turn the ignition switch to the ON position. The neu- ometer backlight (5) must illuminate.

  • Page 81: 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 magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.

  • Page 82: Drive System

    6. Loosen the clamp securing the joint boot to the swing arm; then slip the boot off the swing arm. Drive System SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description.
  • Page 83 13. Support the swing arm from the right side; then using a rubber mallet, drive the axle shaft from the swing arm tube. Account for two O-rings. KM533B 10. Remove the swing arm assembly. Account for the driveshaft spring. KM536 KM508 11.
  • Page 84 KM519 KM543 3. Inspect all splines and hubs for excessive wear, 7. Check the final drive gear case assembly for smooth chips, cracks, or distortion. gear operation. If gears are noisy or if there is any catching or binding, the gear case assembly must be repaired.
  • Page 85 KM920A KM924A 4. Remove the oil seals from the case and cover; then drive the bearings out of the case. KM921 3. Remove the pinion shaft using the pinion puller; then using a three-jaw puller, remove the pinion bearing. Account for the pinion shim. KM925 KM926 KM922...
  • Page 86 KM928 KM928 5. Heat the gear case to approximately 180° F and using 2. Apply grease to the seal lips; then using a seal driver, a blind-bushing puller, remove the pinion needle drive the seals into the gear case and cover (flat side bearing.
  • Page 87 6. Apply grease to the pinion seal lips and install into the gear case until fully seated; then apply a light coating of machinist’s layout dye or paste to several ring gear teeth. 7. Install the proper shims on the ring gear and install into the gear case;...
  • Page 88 If tooth contact pattern is comparable to an incorrect pat- 8. Install six 8 mm and two 10 mm cap screws and tern, correct tooth contact according to the following while rotating the pinion gear, tighten in a crisscross chart. pattern to the specified torque (8 mm cap screws to 19 ft-lb, 10 mm cap screws to 36 ft-lb).
  • Page 89 INSTALLING 1. Install new O-rings in the grooves of the gear case; then grease the center splines of the axle and install in the gear case from the left side. KM530 5. Pack approximately 3 g (0.1 oz) of grease into each swing arm pivot bearing cavity;...

  • Page 90: Front Brake Lever/Master Cylinder Assembly

    KM533B KM502 9. Install the shock absorber using the existing hard- 14. Install the hub nuts and tighten to 72 ft-lb; then ware and tighten to 29 ft-lb; then install the brakeline install new cotter pins and bend as shown. hose clamp on the swing arm and tighten securely.

  • Page 91: Auxiliary Brake Pedal/Master Cylinder Assembly

    2. Install the master cylinder assembly on the handlebar engaging the alignment stud in the hole in the han- dlebar; then secure with the master cylinder clamp and two cap screws. Make sure the UP arrow on the clamp is directed upward. KM116A ...
  • Page 92 2. Compress the reservoir clamp and remove the reser- 3. Using two new crush washers, connect the brake voir hose; then remove the union bolt. Account for hose to the master cylinder with the union bolt; then and discard two crush washers. making sure the spring clamp is seated securely, con- nect the reservoir hose to the master cylinder.

  • Page 93: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy Rear axle shaft serration 1. Replace shaft worn - broken Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Pedal free-play excessive 2.

  • Page 94: Suspension

    INSTALLING 1. Install each shock absorber to the frame and A-arm Suspension with cap screws and nuts. Tighten all nuts to 29 ft-lb. CAUTION The following suspension system components should be Do not tighten the nut beyond the recommended speci- inspected periodically to ensure proper operation.

  • Page 95: Front A-Arms

    2. Inspect the shock absorber body, bottom stop, and rubber bushing for damage and leaking oil. If any defects are found, replace the shock absorber. 3. Inspect the spring, spring seat, and preload adjust- ment collar for damage or corrosion. If corrosion or damage is present on the collar, it must be replaced.
  • Page 96 KM573 SP382 7. Remove the brake hose clamp from the A-arm; then  NOTE: All bearings, bushings, and seals that are remove the cotter pins and slotted nuts securing the removed must be replaced with new ones. upper and lower ball joints. INSTALLING 1.

  • Page 97: Wheels And Tires

    Wheels and Tires TIRE SIZE ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed. Do not under any circumstances substitute tires of a different type or size.

  • Page 98: Troubleshooting

    INSTALLING 2. Inspect the tires for damage, wear, or punctures. 1. Install each wheel on its hub. ! WARNING NOTE: Make sure each wheel is installed on its Do not operate the ATV if tire damage exists.  proper hub as noted in removing (the “rotation NOTE: If repair is needed, follow the instructions ...
  • Page 99 NOTES...
  • Page 100 NOTES...
  • Page 101 NOTES...
  • Page 102 ©2017 Arctic Cat Inc. Effective: February 2017 Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-971...

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