Arctic Cat Y-12+ 2012 Service Manual
  1. Manuals
  2. Brands
  3. Arctic Cat Manuals
  4. Offroad Vehicle
  5. Y-12+ 2012
  6. Service manual
Arctic Cat Y-12+ 2012 Service Manual

Arctic Cat Y-12+ 2012 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2012
Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented
applications.
Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To
service models not included in this manual, please refer to the following publications:
•
2012 Y-12+ Service Manual
•
2012 T-14 Service Manual
•
2012 300 DVX/Utility Service Manual
•
2012 350 Service Manual
•
2012 425 Service Manual
•
2012 700 Diesel Service Manual
•
2012 450 XC Service Manual
•
2012 450/1000 Service Manual
•
2012 550/700 Service Manual
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
www.mymowerparts.com
AT THIS POINT directs the technician to certain
Manual
Table of Contents
September 2011

Advertisement

Table of Contents

Troubleshooting

loading
Need help?

Need help?

Do you have a question about the Y-12+ 2012 and is the answer not in the manual?

Questions and answers

Related Manuals for Arctic Cat Y-12+ 2012

Summary of Contents for Arctic Cat Y-12+ 2012

  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Click on the blue text to go. Service M ervice rv c Manual M n a TABLE OF CONTENTS A A A A A A V V Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below.
  • Page 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-3 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........1-4 Genuine Parts ............
  • Page 4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications Torque Specifications CHASSIS EXHAUST COMPONENTS Brake Type Hydraulic w/Brake Lever Torque Part Part Bolted To Lock and Auxiliary Brake ft-lb N-m Tire Size Front - 25 x 8-12...
  • Page 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions ENGINE/TRANSMISSION (ft-lb/N-m) Torque Part Part Bolted To ft-lb N-m Crankshaft Bushing Crankshaft Speed Sensor Housing Crankcase ft-lb ft-lb ft-lb ft-lb Clutch Shoe** Crankshaft 35.4 69.4 103.4 Clutch Cover/Housing Assembly Crankcase 36.7...
  • Page 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED FRONT During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations DIFFERENTIAL/REAR DRIVE and variations in driving speeds contribute to good LUBRICANT engine break-in.
  • Page 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Store the ATV indoors in a level position. Preparation For Storage CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV caus- CAUTION ing rusting.
  • Page 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Air Filter..............2-3 Valve/Tappet Clearance .......... 2-4 Testing Engine Compression ........2-4 Spark Plug...............
  • Page 9 * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. Manual...
  • Page 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV.  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.
  • Page 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Valve Adjuster Procedure 2. Replace any drain that is cracked or shows any signs of hardening or deterioration.  NOTE: The seat, storage compartment cover CAUTION assembly, compartment box, air filter/filter housing,...
  • Page 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: The engine should be warm (operating tem- Adjust the gap to correct specification (see Section 1 for proper type and gap). Use a feeler gauge to check the gap.
  • Page 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Using the adjustable Oil Filter Wrench and a suitable wrench, remove the old oil filter.  NOTE: Clean up any excess oil after removing the filter. 6. Apply oil to a new filter O-ring and check to make sure it is positioned correctly;...
  • Page 14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: Steps 3-5 are for Mud Pro models; for other models, proceed to step 6. Liquid Cooling System 3. Remove four cap screws securing the snorkel hous- ing to the front inspection panel; then remove two cap screws from the rear of the snorkel housing.
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF142A AL677C 7. Add coolant as necessary; then install the radiator 3. Drain the lubricant into a drain pan by removing in cap, splash guard (if applicable), and access panel or turn the drain plug from each.
  • Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Nuts/Bolts/Cap Screws Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications (see Sec- tion 1).
  • Page 17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD714A CF258A 3. Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- Shift Lever ment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place.
  • Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: During the bleeding procedure, watch the sight glass very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the res- ervoir before the bleeding procedure is continued.
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. 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. CAUTION This hydraulic brake system is designed to use DOT 4 brake fluid only.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed. Checking/Replacing V-Belt REMOVING 1. Remove the right-side footrest (see Section 8). 2. Remove the cap screws securing the V-belt cover...
  • Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ085 GZ485A  NOTE: The arrows on the V-belt should point in  NOTE: At this point, the push-bolt can be removed. direction of engine rotation (forward). 3. Rotate the V-belt and clutches until the V-belt is flush with the top of the driven clutch.
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Troubleshooting ............3-3 Table of Contents ............ 3-5 Manual Table of Contents www.mymowerparts.com...
  • Page 23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission Specifications This section has been organized into sub-sections which VALVES AND GUIDES show a progression for the complete servicing of the Arc- Valve Face Diameter (max) (intake) 31.6 mm tic Cat ATV engine/transmission.
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Repair - replace guides 3.
  • Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 26: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery and Table of Contents the battery vent hose; then remove the battery. CAUTION Battery acid is harmful if it contacts eyes, skin, or cloth- Removing Engine/ Transmission......
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the clamp securing the cooling duct boot to the V-belt housing; then remove the cooling duct boot from the V-belt housing outlet. CD766D 9. Loosen the clamp securing the air intake duct to the air filter housing.
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF138A CD796 16. Remove the two cap screws securing the exhaust 20. Disconnect the speed sensor connector from the sen- pipe to the cylinder head; then remove the pipe. sor housing.
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 26. Raise the rear of the engine enough to allow the rear output flange to clear the output flange joint. Block the engine up in this position. CD788 23. Remove the spark plug wire from the spark plug;...
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD818 CC001D  NOTE: Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated. 2. Remove the 12 cap screws securing the valve cover to the head;...
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD211A CC013D 3. Loosen the cap screw on the end of the tensioner; 6. While holding the chain, slide the sprocket and cam- then remove the two cap screws securing the ten- shaft out of the cylinder head.
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC017D CC022D C. Cylinder D. Piston  NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. 10. Loosen the clamp securing the coolant hose to the union; then detach the hose.
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC025D CC033D  NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Con- necting Rod Holder. CAUTION Do not allow the connecting rod to go down inside the crankcase.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Push the valve from side to side; then from top to bottom. 4. Maximum “wobble” deflection must not exceed specifications. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore;...
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Piston Rings 2. Insert each valve into its original location. 1. Starting with the top ring, slide one end of the ring 3. Install the valve springs with the painted end of the out of the ring-groove.
  • Page 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Piston Pin (Outside Installing Piston Rings Diameter) and Piston-Pin Bore 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the 1.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CYLINDER/CYLINDER HEAD ASSEMBLY  NOTE: If the cylinder/cylinder head cannot be trued, they must be replaced as an assembly. Cleaning/Inspecting Cylinder Head CAUTION The cylinder head studs must be removed for this pro- cedure.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90°...
  • Page 40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Camshaft Spring/Drive 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3. Place the valve cover on the cylinder head and secure 1.
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the two alignment pins into position. Place the 5. Install the coolant hose onto the crankcase union and cylinder gasket into position; then place a piston tighten the clamp.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV1027 CD466 21. Place the C-ring into position in its groove in the cyl- CAUTION inder head. Care must be taken that the tab-washer is installed cor- rectly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD501 CD471 26. Loosen the four adjuster screw jam nuts; then loosen  NOTE: The adjuster shaft will be drawn into the ten- the four adjuster screws on the rocker arms in the sioner as the adjuster screw is rotated clockwise.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 CC003D outer magneto cover.
  • Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the two starter gears from the crankcase not- ing the direction of the beveled side of the gears for installing purposes; then remove the two starter gear shafts.
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Left-Side Components INSPECTING STARTER CLUTCH/GEAR 1. Place the starter clutch gear onto the rotor/fly- wheel and attempt to rotate the starter clutch gear clockwise. It should lock up to the rotor/flywheel.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install 2. Thoroughly clean the gear hub; then apply a drop the new one-way clutch and secure with the cap of green Loctite #620 to the bearing outer race and...
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REPLACING STATOR COIL/ 1. Install the water pump driven gear alignment pin and the driven gear (with the beveled side of the gear fac- TRIGGER COIL ing outward as noted in removing); then secure with the snap ring.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD946A PR447A 4. In order on the crankshaft, install a washer, ring gear, key, and the magneto rotor. Secure with the nut. Tighten to 107 ft-lb. CD944  NOTE: The sharp side of the snap ring should be facing outward.
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins. Make sure the outer shift shaft washer is in place.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD069 CD079 14. Place the water pump into position and secure with 2. Remove the nut and washer securing the movable two cap screws. Tighten securely. drive face; then remove the face. Account for a spacer.
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the fixed drive face. 6. Using an impact driver, remove the cap screws securing the air intake plate; then remove the plate cushion. A. Oil Pump Driven Gear D.
  • Page 54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF088A CD987 10. Remove the two cap screws securing the gear posi- tion switch; then remove the switch. Account for two neutral contact pins and two springs. CD993 13. Using an impact wrench, remove the cap screws secur- ing the final drive carrier bearing housing (E);...
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD895A ATV1014 15. Using an impact driver, remove the three Phillips-head INSPECTING CLUTCH HOUSING screws securing the oil pump; then remove the pump. 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Right-Side Components 1. Install the gear position switch making sure the two neutral contact pins and the two springs are properly positioned. Tighten the cap screws securely. CD988 4. Install the oil pump drive gear spacer onto the crank balancer shaft.
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD985A PR399A CAUTION When installed correctly, the green alignment dot (or the word OUTSIDE) on the one-way clutch is visible. 9. Lightly grease the clutch housing seal; then insert the left fixed-drive spacer.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Slide the fixed drive face onto the clutch shaft. 15. Spread the faces of the driven pulley by threading a cap screw into one of the bosses of the driven fixed face;...
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: At this point, the cap screw can be removed from between the driven pulley faces. 18. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley.
  • Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the reverse idler gear assembly (F). Account for all washers, shaft, bushing, and the gear. CC675 7. Note the timing marks on the crank balancer assem- bly (B) gear and crankshaft (C) gear for assembling CC668 purposes;...
  • Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: Thoroughly clean any sealant from the oil strainer cap. MT011A 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Checking Backlash 1. If removed, install the secondary drive/bevel gear shaft into the crankcase; then tighten the nut to 59 ft-lb. 2. Install the secondary drive bearing support; then install the secondary driven output shaft into the crankcase.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer. ATV-1074 3.
  • Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction.
  • Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ318A GZ318 6. Remove the low driven gear. Account for a bearing, 2. Install the low driven gear locking washer; then bushing, and thrust washer. install the inner reverse driven gear washer.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ287 GZ312 4. Install the outer reverse driven washer; then secure 6. From the opposite end of the countershaft, install the the reverse driven gear assembly with a snap ring.
  • Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 68 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Insert the two shift forks into the sliding dogs noting the direction of the tabs from disassembling; then Joining Crankcase Halves install the shift fork shaft.  NOTE: Make sure the shift fork tabs face upward and that they are properly seated into the shift cams.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. From the left side, place the engine/transmission into the frame; then slide the engine rearward as far as possible. 2. Slightly raise the rear of the engine and engage the front drive coupler into the splines of the front drive output yoke;...
  • Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD793 CD787 8. Secure the engine ground wire to the engine with a cap screw. Tighten to 8 ft-lb. CD785 17. Secure the shift rod to the engine with a new E-clip.
  • Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 22. Place the battery into position in the battery compart- ment; then install the battery cables and vent hose. Secure with the battery cover. CAUTION Battery acid is harmful if it contacts eyes, skin, or cloth- ing.
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Carburetor Schematics..........4-2 Carburetor ............... 4-2 Electric Choke ............4-6 Throttle Cable Free-Play ......... 4-7 Engine RPM (Idle)........... 4-7 Gas Tank ..............4-8 Oil Filter/Oil Pump ...........
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel/Lubrication/Cooling Carburetor  NOTE: Arctic Cat recommends the use of new gas- ! WARNING kets, lock nuts, and seals and lubricating all internal Whenever any maintenance or inspection is performed components when servicing the engine/transmission.
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR162B CC748 8. Disconnect the electric choke lead from the wiring 4. Remove the Phillips-head screws securing the float harness. chamber; then remove the chamber. Account for the O-ring. 9. Disconnect the vent hose; then remove the carbure- tor.
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION DO NOT place any non-metallic components in parts-cleaning solvent because damage or deterioration will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner.
  • Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: Note the locations of the jets and holder dur- ing assembling procedures. CC749 7. Place the U-ring into the pump housing. Position the spring and diaphragm assembly (lip toward the car- buretor) onto the carburetor;...
  • Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CH015D PR162C 5. Place the throttle actuator cover into position on the INSTALLING carburetor; then secure with the screw. 1. Connect the gas and vent hoses onto the carburetor. 2. Connect the electric choke lead to the wiring har- ness.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Throttle Cable Free-Play To adjust the throttle cable free-play, follow this proce- dure. 1. Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster. KC328A 2.
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Connect the gasline hose from the carburetor; then connect the fuel gauge connector. 4. Install the vent hose; then fill the gas tank with gaso- line. 5. Start the engine and inspect for leakage.
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect all fasteners and grommets for damage or wear. Liquid Cooling System Installing 1. Position the fan/fan shroud assembly on the radiator; then secure with existing hardware. When filling the cooling system, use premixed Arctic Cat Antifreeze.
  • Page 81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 D. If the thermostat does not open, it must be 4. Loosen the hose clamps and slide the clamps away from the hose ends approximately 2 in.; then remove replaced.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC785A CD815 2. Connect the two coolant hoses to the water pump and 2. Start the engine. Fuel pump pressure should read secure with the clamps. Tighten securely. 0.18-0.25 kg/cm (2.5-3.5 psi).
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Replace gasket 4. Gas contaminated 4.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Electrical Connections..........5-2 Battery..............5-2 RPM Limiter............. 5-3 Testing Electrical Components ........ 5-3 Accessory Receptacle/Connector ......5-3 Brakelight Switch (Auxiliary)........5-3 Brakelight Switch (Handlebar Control) ....
  • Page 85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Maintenance Charging Electrical System  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is...
  • Page 86 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RPM Limiter  NOTE: The ATV is equipped with a CDI unit that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.
  • Page 87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Wiring Harness Side)  NOTE: The ignition switch must be in the ON position. 1. Set the meter selector to the DC Voltage position. VOLTAGE (Wiring Harness Connector) 2. Connect the red tester to the orange wire; then connect the black tester lead to the red/blue wire.
  • Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Coolant Temperature and Fan Motor Cooling Fan Switches The connector is the black two-prong one located above the radiator. 1. Connect the meter leads (selector in the OHMS position) to the switch contacts.
  • Page 89 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RELAYS 4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. The 4-pin relays are identical plug-in type. Relay func- tion can be checked by switching relay positions. The 5.
  • Page 90 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: If the meter does not read as specified,  NOTE: If the sensor tests are within specifications, replace the spark plug cap. the LCD gauge must be replaced (see Section 8).
  • Page 91 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. The meter must show less than 1 ohm. 10. With the switch in the OFF position, connect the red tester lead and the black tester lead to each of the remaining pins.
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Connect the red tester lead to the yellow/green 2. Connect the red tester lead to the red wire; then wire; then connect the black tester lead to the connect the black tester lead to the white wire.
  • Page 93 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Connect the red tester lead to the white/green wire 3. With the engine running at the specified RPM, all in the supply harness. The meter must show 10.2 wire tests must show 60 AC volts.
  • Page 94 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TESTING VOLTAGE Perform this test on the starter motor positive terminal. To access the terminal, slide the boot away.  NOTE: The ignition switch must be in the ON posi- tion, the engine stop switch in the RUN position, and the shift lever in the NEUTRAL position.
  • Page 95 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Secure the positive cable to the starter motor with  NOTE: The LO beam is the outside bulb, and the HI the nut. beam is the inside bulb. 3. Connect the battery (positive cable first).
  • Page 96 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Attach the Timing Light to the spark plug high ten- sion lead; then remove the timing inspection plug Ignition Timing from the left-side crankcase cover. 2. Using the Tachometer, start the engine and run at 1500 RPM;...
  • Page 97 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Charge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter relay defective 3. Replace relay 4.
  • Page 98 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM/ BRAKE SYSTEM TABLE OF CONTENTS Drive System/Brake System........6-2 Front Drive Actuator/Differential Lock...... 6-2 Front Differential ............6-3 Drive Axles ............6-16 Rear Gear Case ............ 6-19 Hub................
  • Page 99 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive System/Brake Front Drive System Actuator/Differential Lock  NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and  NOTE: The actuator is not a serviceable compo- are not designed to depict actual conditions.
  • Page 100 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AG928 AG926  NOTE: It is important to tighten this cap screw while INSTALLING the others are loose to ensure proper seating of the  NOTE: Make sure to properly align the differential actuator.
  • Page 101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut and washer. AF896D 10. Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft;...
  • Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF897D PR725A 14. Remove the upper A-arm lock nuts and cap screws; 16. Remove the inner fender panels. then remove the A-arms. 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case;...
  • Page 103 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD016 GC004A 20. Free the differential assembly from the frame mount- 2. Using a rubber mallet, remove the housing. Account ings; then shift the differential assembly forward for a gasket. Remove the fork, collar, and spring.
  • Page 104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD107 KX219 5. Using a seal removal tool, remove the input shaft Assembling Input Shaft seal. Account for a spacer. 1. Place the pinion housing in a press and install the input shaft bearing.
  • Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GC014 CD099 3. Lubricate the input shaft with High-Performance #2 5. Place the pinion housing with new gasket onto the Molybdenum Disulphide Grease packing the boot gear case housing; then secure with the existing cap ribs and splines;...
  • Page 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GC003 KX177 3. Using a plastic mallet, tap lightly to remove the dif- ferential cover. Account for an O-ring. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly.
  • Page 107 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Disassembling Pinion Gear  NOTE: Any service of the pinion gear or related bearings will require a new gear case/differential housing. The removal of the lock collar severely dam- ages the threads in the housing.
  • Page 108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC884 CC891 3. Coat a new needle bearing and the bearing pocket of Shimming Procedure/Shim Selection a new gear case/differential housing with red Loctite #271; then using a suitable driver, install the bearing lightly seated against the bearing seats.
  • Page 109 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GC031A GC033A 2. Install the ring gear with shim in the gear case; then 4. Install the existing shim or a 0.063 in. shim on the while holding the pinion stationary, rock the ring cover side of the ring gear;...
  • Page 110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.
  • Page 111 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GC036B CF275A 5. Making sure the O-ring is properly positioned on the  NOTE: The spider and ring gear assembly must be differential housing cover assembly, install the cover replaced as a complete unit.
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb. CF278 CAUTION Make sure the tool is free of nicks or sharp edges or CD103 damage to the seal may occur.
  • Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AG925 AF896D 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this sec- tion). 6. Secure the upper A-arms with cap screws and lock nuts.
  • Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Pump up the hand brake; then engage the brake lever lock. 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock.
  • Page 115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DISASSEMBLING/INSPECTING/ASSE- MBLING AXLES To disassemble/inspect/assemble the axles, follow the instruction contained in the appropriate boot repair kit. INSTALLING REAR DRIVE AXLE 1. Push the axle shaft into the CV cup to release the detent balls;...
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Check the front differential oil level and add oil as necessary. AT THIS POINT  For servicing the input shaft, pinion gear, needle bear- ing, ring gear, and axle seal, see Front Differential in this section.
  • Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX041 GC058A 3. Remove the hex nut securing the hub. 3. If clearance is as specified, remove the ring gear and thrust button; then place a drop of red Loctite #271 4.
  • Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Hand Brake Lever/Master Cylinder Assembly  NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con- tainer.
  • Page 119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 BC205 DE058A 5. Remove the clamp screws securing the brake hous- 2. Using two new crush washers, connect the banjo-fit- ing to the handlebar; then remove the assembly from ting to the master cylinder; then secure with the the handlebar.
  • Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service.
  • Page 121 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR713A PR715 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid.
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR719C PR238 4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented.  NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly.
  • Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel...

  • Page 124: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-6 Troubleshooting ............7-8...

  • Page 125: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing.

  • Page 126: Front A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the ATV from the support stand. Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING...
  • Page 127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF616D AF610D 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount; then secure the hose to the A-arm with a cable tie and grommet.

  • Page 128: Rear A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF618D CD008 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten to 40 ft-lb (steel wheels) install the hub assembly onto the drive axle.

  • Page 129: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Slide the hub out of the knuckle and set aside.  NOTE: Ensure that the brake hose is properly routed and secured to the upper A-arm. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms.
  • Page 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 The ATV is equipped with low-pressure tubeless tires of  NOTE: Make sure each wheel is installed on its the size and type listed in Section 1. Do not under any proper hub as noted in removing (the “rotation...

  • Page 131: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber 3. Shock absorber preload too low 3. Adjust shock absorber preload...
  • Page 132 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME/CONTROLS TABLE OF CONTENTS Steering/Frame/Controls ..........2 LCD Gauge ..............2 Steering Post/Tie Rods ..........2 Handlebar Grip ............5 Throttle Control ............6 Steering Knuckles ............6 Measuring/Adjusting Toe-Out ........

  • Page 133: Steering/Frame/Controls

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame/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, cracked, and has equal and complete full-left and full-right capability.
  • Page 134 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Unlatch the storage compartment lid; then slide the storage compartment cover assembly forward and lift off. CD760 8. Using a suitable lift stand, raise the ATV enough to remove the front wheels.
  • Page 135 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Remove two cap screws securing the lower steering 2. Place the upper steering post bearings into the hous- post bearing flange to the frame; then remove the ings; then position on the steering post and secure the steering post.

  • Page 136: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Handlebar Grip REMOVING 1. Loosen but do not remove the cap screws in the end of the handlebar; then tap lightly on the head to dis- lodge the handlebar plug.

  • Page 137: Throttle Control

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 3. Wipe off any excess glue; then secure the grip with the handlebar end-cap. 1. Place the return spring into the throttle control; then place the bushing and actuator arm into position.
  • Page 138 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the hub assembly. 6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. 7. Remove the two cap screws securing the ball joints in the knuckle.

  • Page 139: Measuring/Adjusting Toe-Out

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring/Adjusting Toe-Out 1. Thoroughly wash the ATV to remove excess weight (mud, etc.). 2. Refer to the specifications and ensure the tires are properly inflated to the recommended pressure.  NOTE: Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur.
  • Page 140 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF785D AF778D  NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to disturb the handlebar position. 8. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the belly panel).

  • Page 141: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals and/or reflectors. INSTALLING 1. Place the rack into position on the frame and front fender panel. Install the cap screws and lock nuts and finger-tighten only.
  • Page 142 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the ignition switch retaining ring and two reinstallable rivets securing the instrument pod; then remove the instrument pod. FI465A FI463A FI466A 2. Unlock the storage compartment lid; then slide the storage compartment cover assembly forward and lift off the storage compartment.
  • Page 143 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF237A CD681 9. Rotate the handlebar to the full-left position; then lift and slide the panel to the rear and lift the rear up to clear the handlebar. FI470A 7. Remove the left and right footwells; then remove the shift knob.
  • Page 144 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the headlight connectors to the appropriate headlights and the front accessory plug wires to the accessory plug. FI468 CD681 3. Make sure the rubber grommets and bushings are in place;...

  • Page 145: Footrests

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Footrests Exhaust System REMOVING REMOVING MUFFLER 1. Remove the machine screws and flange nuts secur- 1. Remove the two exhaust springs at the muf- ing the front and rear fenders to the footwells.

  • Page 146: Taillight Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install one shoulder screw and three plastic rivets (on each side) to secure the front of the rear body panel to the footwells. CD691A 3. Remove two machine screws securing the battery cover and remove the cover.

  • Page 147: Seat

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect all wires for corroding, pinching, and crack- ing. Seat 3. Inspect the bulb for wattage, voltage, and proper operation. INSTALLING REMOVING/INSTALLING 1. Place the assembly into position on the frame and 1.

This manual is also suitable for:

T-14 2012300 dvx 2012300 utility 2012350 2012425 2012700 diesel 2012 ... Show all

Table of Contents