Arctic Cat 366 ATV 2008 Service Manual
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Arctic Cat 366 ATV 2008 Service Manual

Arctic Cat 366 ATV 2008 Service Manual

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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 the 2008 Arc-
tic Cat 366 ATV. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The
symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-
tive because it deals with the possibility of damaging part or parts of the ATV. The symbol
NOTE: identifies
AT THIS POINT directs the tech-
supplementary information worthy of particular attention. The symbol
nician to certain 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.
© 2008 Arctic Cat Inc.
January 2008
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Click on the red text to go. Foreword MORE TO GO ON. Section General Information/Specifications Periodic Maintenance 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System 6. Drive System Suspension 8. Steering/Frame...

  • Page 3: Table Of Contents

    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 Tightening Torque (General Bolts) ......1-3 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........

  • Page 4: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* Torque Specifications EXHAUST COMPONENTS CHASSIS Torque Brake Type Hydraulic w/Brake Lever Lock Part Part Bolted To and Auxiliary Brake ft-lb N-m Tire Size Front - 24 x 8-12...

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

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions ENGINE/TRANSMISSION Torque (ft-lb/N-m) Part Part Bolted To ft-lb Clutch Shoe** Crankshaft Clutch Cover/Housing Assembly Crankcase ft-lb ft-lb ft-lb ft-lb Left-Side Cover Crankcase 35.4 69.4 103.4 Crankcase Half (6 mm) Crankcase Half 13.5...

  • Page 6: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE/ TRANSMISSION OIL Break-In Procedure ! CAUTION Any oil used in place of the recommended oil could A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are cause serious engine damage.

  • Page 7: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FILLING GAS TANK 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. ! WARNING 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire Always fill the gas tank in a well-ventilated area.

  • Page 8: Www.mymowerparts.com

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Check all control cables for signs of wear or fray- 6. Check the entire brake systems (fluid level, pads, ing. Replace if necessary. etc.), all controls, lights, and headlight aim; adjust or replace as necessary.
  • Page 9 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 Battery..............2-3 Fuses ..............2-4 Air Filter ..............2-4 Valve/Tappet Clearance (Feeler Gauge Procedure) ........

  • Page 10: Periodic Maintenance Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace T = Tighten Initial Service Every Every 3 Every 6...

  • Page 11: Periodic Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Periodic Maintenance Battery After being in service, batteries require regular cleaning This section has been organized into sub-sections and recharging in order to deliver peak performance and which show common maintenance procedures for the maximum service life.

  • Page 12: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. When using an automatic battery charger, 11. Connect the battery cables (positive cable first); always follow the charger manufacturer’s then install the battery hold-down. instructions. ! CAUTION B. When using a constant-current battery charger, use the following Battery Charging Chart.
  • Page 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Foam Air Filter Cleaner and Foam Air Fil- ter Oil are available from Arctic Cat. 4. Dry the element. 5. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element.

  • Page 14: Valve/Tappet Clearance (Feeler Gauge Procedure)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications.

  • Page 15: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Testing Engine Compression To test engine compression, use the following proce- dure. 1. Remove the high tension lead from the spark plug. 2. Using compressed air, blow any debris from around the spark plug.

  • Page 16: Spark Plug

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Spark Plug Muffler/Spark Arrester A light brown insulator indicates that a plug is correct. At the intervals shown in the Periodic Maintenance A white or dark insulator indicates that the engine may...

  • Page 17: Adjusting Throttle Cable

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Turn the idle adjustment screw clockwise one turn past the recommended RPM setting; then turn it Adjusting Throttle counterclockwise to 1250-1350 RPM. Cable To adjust the throttle cable free-play, follow this proce- dure.
  • Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. ! CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is above the L”...

  • Page 19: Front Differential/Rear Drive Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC163D KC0077A 3. Drain the oil into a drain pan by removing the AT THIS POINT drain plug from each. To check/service oil strainer, see Section 3. 4. Place the oil strainer into position beneath the crankcase and secure with the cap screws.

  • Page 20: Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Tires Suspension/Shock Absorbers/Bushings TIRE SIZES The following suspension system components should The ATV is equipped with low-pressure tubeless tires be inspected periodically to ensure proper operation. of the size and type listed (see Section 1). Do not under any circumstances substitute tires of a different type or A.

  • Page 21: Lights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Lights Rotate the ignition switch to the lights position; the headlights and taillights should illuminate. Test the brakelights by compressing the brake lever. The brake- lights should illuminate. HEADLIGHTS NOTE: The bulb portion of a headlight is fragile.
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING/ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizon- tally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming.

  • Page 23: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Shift Lever CHECKING ADJUSTMENT KC194A 3. Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- ment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place.
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 738-420A PR377C NOTE: During the bleeding procedure, watch the reservoir sight glass very closely to make sure there is always a sufficient amount of brake fluid. When the sight glass changes from dark to light, refill the reservoir before the bleeding procedure is continued.

  • Page 25: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove a front wheel. 2. Measure the thickness of each brake pad. 3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced.
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC149A KC128 2. Slide the auxiliary brake pedal part way off the 4. Thread a cap screw from the V-belt cover into the pivot stud but do not remove; then remove the cap...
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. With two drops of red Loctite #271 on the threads and with the splines of the clutch shaft protruding through the movable drive face, install the nut and tighten to 147 ft-lb.
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder; then secure with the flat washer and cap screw and tighten to 20 ft-lb. KC153A www.mymowerparts.com...
  • Page 29 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 ............3-3 Troubleshooting ............3-4 366 Table of Contents ..........3-7 www.mymowerparts.com Back to TOC...

  • Page 30: Special Tools

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SPECIAL TOOLS Engine/Transmission A number of special tools must be available to the technician when performing service procedures in this section. This section has been organized into sub-sections Description which show a progression for the complete servicing of the Arctic Cat ATV engine/transmission.
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* VALVES AND GUIDES CYLINDER, PISTON, AND RINGS Valve Face Diameter (intake) 30.6 mm (1.20 in.) Piston Skirt/Cylinder Clearance 0.060-0.073 mm (exhaust) 27.0 mm (1.06 in.) (0.0024-0.0029 in.) Valve/Tappet Clearance (intake) 0.076-0.127 mm...
  • Page 32 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. Replace cylinder head 3.
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine noisy (Noise seems to come from timing chain) Condition Remedy 1. Chain stretched 1. Replace chain 2. Sprockets worn 2. Replace sprockets 3. Tension adjuster malfunctioning 3. Repair - replace adjuster...
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine runs poorly at high speed Condition Remedy 1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed 2. Valve springs weak 2. Replace springs 3.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the heat shield; then remove the gas tank (see Section 4). Table of Contents 3. Remove the oil fittings from the engine and (366) account for two O-rings; then disconnect the oil temperature connector and cooling fan connector.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring.

  • Page 37: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC228B KC216 8. Remove the front and rear V-belt cooling boots from the V-belt housing. Top-Side Components 9. Remove the cap screws from the front and rear output flanges; then remove the front and rear engine mounting through-bolts.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1264 MD1245 4. Remove the cam chain tensioner pivot cap screw NOTE: Keep the mounting hardware with the cov- and washer. ers for assembly purposes. 2. Remove the valve cover cap screws. Note the rub- ber washers on the four top-side cap screws;...
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Using an awl, rotate the C-ring in its groove until 9. Remove the four cylinder head cap screws and it is out of the cylinder head; then remove the washers.
  • Page 40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder D. Piston NOTE: Steps 1-11 in the preceding sub-section must precede this procedure. 12. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half.

  • Page 41: Servicing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indica- tion of high spots.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the valve seal and the lower remaining 2. Acceptable diameter range (intake valve) must be spring seat. Discard the valve seal. within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC131D 3. Push the valve from side to side; then from top to bottom.
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PISTON ASSEMBLY Measuring Piston-Ring End Gap (Installed) NOTE: Whenever a piston, rings, or pin are out of 1. Place each piston ring in the wear portion of the tolerance, they must be replaced.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1069 ATV-1085B 2. Install the compression rings (1 and 2) so the let- Measuring Piston Skirt/ ter(s) on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring...
  • Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the cylinder head on the surface plate cov- 2. Inspect the cylinder for pitting, scoring, scuffing, ered with #400 grit wet-or-dry sandpaper. Using warpage, and corrosion. If marks are found, repair...
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC127D ATV-1068A 2. Wash the cylinder in parts-cleaning solvent. Measuring Camshaft Runout 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the sur- NOTE: If the camshaft is out of tolerance, it must face using a ball hone.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.

  • Page 49: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF060A MD1343A 2. If damaged, the camshaft must be replaced. ! CAUTION Incorrect installation of the piston rings will result in engine damage. Installing Top-Side Components 1. Install the piston on the connecting rod making...
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing;...
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. With the alignment pin installed in the camshaft and the cam lobes directed down (toward the pis- ton), place the camshaft in position and verify that the timing mark on the magneto is visible through...
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the pis- ton). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes.

  • Page 53: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 27. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. MD1146 23. Place the cam chain tensioner assembly and gasket...

  • Page 54: Removing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Left-Side Components A. Cover/Stator Assembly 1. Remove the cap screws securing the outer mag- neto cover and remove the cover. 2. Remove the left-side cover-to-crankcase mounting cap screws noting the location of the 8 mm cap...
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Using Magneto Rotor Remover, break the rotor/flywheel assembly loose from the crankshaft. Remove the remover, the crankshaft protector, the rotor/flywheel, and the starter clutch gear. Account for the key.

  • Page 56: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the cam stopper assembly. 5. Install the gear shift shaft assembly and washer making sure to align the alignment marks. MD1122 Installing Left-Side MD1239 Components 6. Install starter idler gear (No. 2) and starter idler gear (No.

  • Page 57: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Right-Side Components AT THIS POINT To service center crankcase components only, pro- ceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove and disassemble only those components which...
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1034 MD1068 8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5. Remove the V-belt. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half.
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the cap screw holding the gear shift posi- tion switch onto the right-side crankcase half. MD1014 KC324A 12. Remove the gear shift position switch. Account for a spacer.
  • Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1017 MD1060 18. Remove the snap ring holding the oil pump driven 21. Remove the four cap screws securing the oil gear. strainer cover; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring.

  • Page 61: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must Servicing Right-Side be replaced. Components NOTE: The oil pump is a non-serviceable compo- nent and must be replaced as a complete assem- bly.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1060 MD1017 4. Place the pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC325A MD1117 12. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; then install and tighten securely. KC326B B. Clutch Cover C.

  • Page 64: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Slide the fixed drive face assembly onto the front shaft. 15. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face...

  • Page 65: Separating Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining pur- poses. MD1313 Disassembling Crankcase Half 1.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1326 KC325 4. Remove the shift fork shaft and the outer shift 7. Remove the counterbalance gear. Account for the fork. key. 8. Remove the counterbalance shaft. MD1327 5. Remove snap ring and gear from the output side of the gear cluster.

  • Page 67: Servicing Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Remove the secondary drive gear/secondary NOTE: Continue to remove, measure, and install driven gear retaining nut. From inside the crank- until backlash measurement is within tolerance. case using a rubber mallet, drive out the output Note the following chart.
  • Page 68 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-0104 CC290D 2. Maximum diameter must not exceed specifica- Correcting Tooth Contact tions. Measuring Connecting Rod NOTE: If tooth contact pattern is comparable to (Small End Deflection) the correct pattern illustration, no correction is necessary.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod 2. Acceptable width range must be within specifica- tions. (Big End Width) COUNTERSHAFT 1. Using a calipers, measure the width of the connecting rod at the big-end bearing.

  • Page 70: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Apply a liberal amount of oil to the crankshaft bearing. Using a propane torch, heat the bearing Assembling Crankcase until the oil begins to smoke; then slide the crank- Half shaft assembly into place.
  • Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Install the input driveshaft. KC325 7. Align the inner shift fork with the gear cluster and with the inner washer in place, install the gear MD1326 10. Install the washer, spacer, sleeve, and reverse idler cluster and inner shift fork.

  • Page 72: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Joining Crankcase Halves 1. Verify that the two alignment pins are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces.
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Align the front and rear output flanges with the 5. Connect the stator coil, trigger coil, and gear shift drive couplers; then secure with the screws and position switch connectors; then attach the engine tighten to 20 ft-lb.
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC238 KC254 9. Install the shift rod onto the shift arm with bushing and flat washer and secure with an E-clip; then connect the speedometer sensor plug. KC170 7. Place the carburetor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe;...
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. If the brake pedal was removed during disassem- bling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. Tighten to 20 ft-lb.

  • Page 76: Fuel/Lubrication/Cooling

    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 Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-2 Throttle Cable Free-Play ......... 4-8 Engine RPM (Idle)........... 4-8 Gas Tank ..............

  • Page 77: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel/Lubrication/ Carburetor Schematic Cooling NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the throttle arm cover; then loosen the jam nut on the throttle cable and remove the throt- tle cable from the throttle arm. The carburetor can now be removed for service.
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Lift the float assembly from the carburetor. Account for the float valve and clip. CC748 4. Remove the Phillips-head screws securing the float chamber; then remove the chamber. Account for the O-ring.
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the slow jet is obstructed, the mixture will be extremely lean at idle and part-throttle oper- ation. 11. Inspect the float valve for wear or damage. 12. Inspect the carburetor mounting flange for damage and tightness.
  • Page 81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Place the float assembly (with float valve) into posi- tion and secure to the carburetor with the float pin. CC761A 3. Install the starter jet and slow jet. Tighten securely.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC0022A KC0019A 7. Place the U-ring into the pump housing. Position INSTALLING the spring and diaphragm assembly (lip toward the carburetor) onto the carburetor; then secure the assembly with the pump housing and three screws.

  • Page 83: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC258A KC257 5. Install the gas tank (see Gas Tank in this section). Throttle Cable Free-Play To adjust throttle cable free-play, see Section 2. Engine RPM (Idle) KC266 3. Install the carburetor onto the engine making sure To adjust the idle RPM, see Section 2.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC219A KC260 3. Remove the gas tank cap; then remove the gas tank cover. Place gas tank cap back on tank. KC262 CLEANING AND INSPECTING KC220 4. Remove the gas tank valve knob.

  • Page 85: Oil Filter/Oil Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC252A KC219A 2. Using a suitable block, support the rear of the tank 5. Install the side panels and seat making sure it locks and connect the gasline hose to the gas tank valve securely in place.

  • Page 86: Oil Cooler

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Oil Cooler KC267 NOTE: Some oil seepage may occur when install- ing the oil pressure gauge. Wipe up oil residue 5. Machine Screw 10. Hose with a cloth. 1. Oil Cooler Assy 6.

  • Page 87: Troubleshooting

    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 88 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 Specifications ............5-2 Battery..............5-2 RPM Limiter............. 5-2 Testing Electrical Components ........ 5-2 Accessory Receptacle/Connector ......5-2 Brakelight Switch (Pressure) ........5-3 Oil Temperature and Cooling Fan Switches ....

  • Page 89: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System RPM Limiter This section has been organized into sub-sections NOTE: The ATV is equipped with a CDI that which show procedures for the complete servicing of retards ignition timing when maximum RPM is the Arctic Cat ATV electrical system.

  • Page 90: Brakelight Switch (Pressure)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. When the brake pedal is depressed, the meter must show less than 1 ohm. Brakelight Switch NOTE: If the meter shows more than 1 ohm of (Pressure) resistance, replace the switch.

  • Page 91: Fan Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Apply thread tape to the threads of the switch; then NOTE: If the meter shows more than 1 ohm of install the switch and tighten securely. resistance, troubleshoot replace switch/component, the connector, or the switch 9.

  • Page 92: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the black tester lead to ground. NOTE: When testing the HI fuse holder, the head- light dimmer switch must be in the HI position; 3. The meter reading must be within specification.

  • Page 93: Speed Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the meter selector to the DC Voltage position; 3. Install the new speed sensor into the housing with then disconnect the black/yellow and black pri- new O-ring lightly coated with multi-purpose mary wires from the coil.

  • Page 94: Handlebar Control Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE RESISTANCE (HI Beam) 1. Set the meter selector to the OHMS position. ! CAUTION 2. Connect one tester lead to the brown/black wire; Always disconnect the battery when performing then connect the other tester lead to the lavender resistance tests to avoid damaging the multimeter.

  • Page 95: Front Drive Selector Actuator

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE NOTE: Resistance tests should be made with the connector disconnected and on the selector-side 1. Select the 2WD position on the front drive selector of the connector. switch; then disconnect the connector on the actu- ator wiring harness.

  • Page 96: Stator Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Charging Coil) 2. Select the OHMS position on the tester and con- nect the red tester lead to the lavender/red wire; then move the gear shift lever to the R (reverse) ! CAUTION position.

  • Page 97: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Make sure that the ignition switch is in the NOTE: If the meter showed no voltage, inspect ON position, transmission in neutral, brake lock ground connections, starter motor lead, battery...

  • Page 98: Regulator/Rectifier

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Prior to replacing the CDI unit to assure the CDI unit is defective, it is advisable to perform a CDI peak voltage test (see Ignition Coil in this section) and/or perform a continuity test of the wiring har- ness from the CDI connector to the CDI unit.

  • Page 99: Running Lights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the meter selector to the DC Voltage position. Back-Up Lights 2. Connect the black tester lead to the black wire; then connect the red tester lead to the brown/blue wire.

  • Page 100: Ignition Timing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. If the meter shows battery voltage, troubleshoot the gear shift position switch connector or the Ignition Timing gear shift position switch. B. If the meter does not show battery voltage, inspect the LIGHTS fuse, ignition switch, or The ignition timing cannot be adjusted;...
  • Page 101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Magneto overcharges Condition Remedy 1. Internal battery short circuited 1. Replace battery 2. Regulator/rectifier resistor damaged - defective 2. Replace resistor 3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection...
  • Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-14 Rear Gear Case ............ 6-18 Hub................

  • Page 103: Drive System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SPECIAL TOOLS Drive System A number of special tools must be available to the technician when performing service procedures in this section. NOTE: Some photographs and illustrations used Description in this section are used for clarity purposes only...

  • Page 104: Front Differential

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC294A KC295A 4. Loosen but do not remove the mounting cap screw 4. Loosen the front cap screw; then tighten the cap at the front of the actuator; then slide the actuator screw on the driveshaft side.
  • Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV0082A AF628D 3. Remove the front wheels. 9. Pull the steering knuckle away from the axle tak- ing care not to damage the seals as the axle clears 4. Pump up the hand brake; then engage the brake the knuckle.
  • Page 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC291A CD106 3. Using a side-cutter (or suitable substitute), remove Disassembling Input Shaft the boot clamps; then remove the boots and splined drive from the input shaft. NOTE: This procedure can be performed on a 4.
  • Page 107 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF983 AF993 AF984 AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulphide Grease.
  • Page 108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the cap screws securing the pinion hous- ing. Account for the coupler, fork, and spring. KX222 4. Install the input shaft into the housing; then install the front boot and secure with an appropriate boot...
  • Page 109 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX178 CC875 5. Place the differential with the open side down; then lift the housing off the spider assembly. Account for shim(s) and mark as right-side. CC876 7. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
  • Page 110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Gear Case Side - install a 1.3-1.4 mm shim and NOTE: If gears are being replaced, use the exist- tighten the bolts to 25-31 ft-lb. Verify backlash ing shims. The numbers are scribed onto the to be within a range of 0.28-0.38 mm...
  • Page 111 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC884 CC892 3. Install the pinion gear assembly into the housing. 6. Install the shift fork assembly making sure the fork Using the 48 mm Internal Hex Socket, secure the leg is facing upward.
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD110 CF267A 8. Install the proper shim onto the ring gear spider 10. Apply a liberal amount of grease to the O-ring; assembly making sure the chamfer side of the then install it on the assembled cover assembly shim is facing toward the ring gear.
  • Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC886 CC889 3. Using a flat-nosed punch, drive the bearing out of 3. Install the pinion shaft and secure with the existing the housing. 48 mm lock collar. Tighten to 125 ft-lb.
  • Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC899 CF278 2. Using a press, remove the bearing. 5. Repeat steps 1-4 for the opposite side. INSTALLING DIFFERENTIAL 1. Align the input flange with the front output flange; then place the differential into position on the frame and install the cap screws and nuts.

  • Page 115: Drive Axles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive Axles REMOVING REAR DRIVE AXLES 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the sup- AF610D port stand to avoid injury.
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If a boot is damaged in any way, it must be replaced with a boot kit. 3. Inspect the gear case seals for nicks or damage. DISASSEMBLING AXLES 1. Using a side-cutters (or suitable substitute), remove the large clamp from the boot.
  • Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Apply 40 grams (1/3 of contents) of grease from NOTE: The recess of the bearing must face the Grease Pack into the knuckles and the new out- toward the housing.
  • Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD024 CD022 ! CAUTION ASSEMBLING AXLES The bearing ring must go onto the shaft with the 1. Install the inner boot with the small clamp making side without splines facing toward the small clamp sure the ends of the clamp are positioned correctly.

  • Page 119: Rear Gear Case

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Tighten the hub hex nut (from step 2) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut.

  • Page 120: Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the sup- KC169 port stand to avoid injury.

  • Page 121: Hydraulic Brake Caliper

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install the hub assembly onto the shaft. 2. Drain the brake fluid from the caliper, hose, and master cylinder. 4. Secure the hub assembly with the nut. Tighten only until snug.
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. PR240A CLEANING AND INSPECTING 1. Clean all caliper components (except the brake PR238 pads) with parts-cleaning solvent.

  • Page 123: Troubleshooting Drive System

    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 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 ............7-2 Rear A-Arms ............7-3 Wheels and Tires ............ 7-4 Troubleshooting ............7-6 www.mymowerparts.com...

  • Page 125: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension Front A-Arms REMOVING NOTE: Critical torque specifications are located in Section 1. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels.

  • Page 126: Rear A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the knuckle assembly onto the ball joints and secure with cap screws. Tighten to 35 ft-lb. 6. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle.

  • Page 127: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Secure the brake caliper to the knuckle with the two cap screws (right side only). Tighten the cali- per to 20 ft-lb. 7. Compress the hand brake lever and engage the brake lever lock;...

  • Page 128: Tire Inflation Pressure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0.28 kg/cm² (4.0 psi). REMOVING 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.

  • Page 129: 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 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-3 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-5 Front Rack ............... 8-6 Front Bumper Assembly .......... 8-6 Front Body Panel/Fender.........

  • Page 131: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame NOTE: Critical torque specifications are located in Section 1. Steering Post/Tie Rods KC184A REMOVING NOTE: If tie rods are to be completely removed, 1. Remove the front body panel/fender (see Front remove the outer tie rod ends from the knuckles at Body Panel/Fender in this section).

  • Page 132: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Inspect the handlebar tube for cracks, wear, or 4. Place the handlebar and caps in place on the steer- unusual bends. ing post and with the handlebar correctly posi- tioned, tighten the cap screws to 20 ft-lb.

  • Page 133: Steering Knuckles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC308 PR287A 3. Using a sharp utility knife, split the handlebar grip from end to end and peel off the rubber. 4. Using an adhesive solvent, clean all glue residue from the handlebar.

  • Page 134: Measuring/Adjusting Toe-In

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR287A KC283 2. Install the knuckle to the upper and lower ball 8. Pump the hand brake lever; then engage the brake joints and secure with the two cap screws. Tighten lever lock.

  • Page 135: Front Rack

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING 6. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the belly panel). NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 136: Front Body Panel/Fender

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Body Panel/Fender REMOVING 1. Remove the seat and both side panels. 2. Remove the front rack; then disconnect the head- light/running light connectors located on the frame. KC220 4. Remove the shift knob; then remove the shift mechanism splash shield.

  • Page 137: Exhaust System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC210G KC224 7. Remove the front body panel/fender panel. 3. Install the screws securing the front body to the front body supports; then install the left-side and CLEANING AND INSPECTING right-side footwell fasteners.

  • Page 138: Rear Body Panel/Rack

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the muffler internally by shaking the muf- fler back and forth and listening for rattles or loose debris inside the muffler. NOTE: For additional details on cleaning the muf- fler/spark arrester, see Section 2.
  • Page 139 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC279 KC320A 2. Connect the light connectors and secure to the CLEANING AND INSPECTING frame; then install the battery, starter relay, and auxiliary brake. Connect all wiring making sure to connect the positive cables first.

  • Page 140: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure low 3. Adjust pressure 4.

  • Page 141: Controls/Indicators

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-2 www.mymowerparts.com LCD Gauge ............. 9-3 Back to TOC...

  • Page 142: Throttle Control

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the banjo-fitting and bolt for cracks and deterioration and the condition of the fittings Hand Brake Lever/ (threaded and compression). Master Cylinder INSTALLING Assembly 1. Position the brake housing on the handlebar.
  • Page 143 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 LCD Gauge REPLACING To replace the LCD gauge, use the following proce- dure. 1. Remove the electric panel and disconnect the LCD gauge connector; then remove three mounting screws (two in front and one in back of gauge) and remove the gauge.

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