Arctic Cat 450 2010 Service Manual
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Arctic Cat 450 2010 Service Manual

Arctic Cat 450 2010 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 2010 Arc-
tic Cat 450 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. 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
AT THIS POINT directs the technician to certain
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.
© 2009 Arctic Cat Inc.
November 2009
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 SHARE OUR PASSION. Click on blue text to go. Foreword Section General Information/Specifications Periodic Maintenance 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System 6. Drive System Suspension 8. Steering/Frame Controls/Indicators...

  • Page 3: Table Of

    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 ..........1-3 Gasoline - Oil - Lubricant ........

  • Page 4: Torque Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SUSPENSION COMPONENTS (Front) General Specifications* Torque Part Part Bolted To ft-lb N-m A-Arm Frame Shock Absorber Frame CHASSIS Shock Absorber (Lower) Upper A-Arm Brake Type Hydraulic w/Brake Lever Lock and...
  • Page 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions Break-In Procedure (ft-lb/N-m) A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are ft-lb ft-lb ft-lb ft-lb most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum 35.4...
  • Page 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE/ TRANSMISSION OIL CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation.
  • Page 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Check all control wires and cables for signs of CAUTION wear or fraying. Replace if necessary. If the interior of the air filter housing is dirty, clean the 4. Change the engine/transmission oil and filter.
  • 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 (Feeler Gauge Procedure) ........2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) ........

  • Page 9: Periodic Maintenance

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval and strainer inspection can be increased to every 1,000 miles or every year.
  • Page 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING FILTER Periodic Maintenance 1. Remove the seat; then remove the cap screws securing the storage compartment. This section has been organized into sub-sections 2. Raise the storage compartment cover; then slide which show common maintenance procedures for the the cover forward and off the compartment.
  • Page 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Using a feeler gauge, check each valve/tappet CAUTION clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster A torn air filter element can cause damage to the ATV screw until the clearance is within specifications.
  • Page 12 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 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the three cap screws securing the spark arrester assembly to the muffler; then loosen and Spark Plug remove the arrester. A light brown insulator indicates that a plug is correct.
  • Page 14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Turn the engine off and wait approximately one minute. 10. Remove the oil level stick and wipe it with a clean cloth. 11. Install the oil level stick and thread into the engine case.
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 To change the lubricant, use the following procedure. 1. Place the ATV on level ground. 2. Remove each fill plug. CC163D  AT THIS POINT To check/service oil strainer, see Section 3.
  • Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TAILLIGHT-BRAKELIGHT NOTE: If the differential/rear drive lubricant is contaminated with water, inspect the drain plug, To replace the taillight-brakelight bulb, use the follow- fill plug, and/or bladder. ing procedure. 1. Turn the bulb socket assembly counterclockwise CAUTION and remove from the housing.
  • Page 17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: There should be an average operating Stop the ATV completely and shift the transmission into the R position. The reverse gear indicator light load on the ATV when adjusting the headlight aim.
  • Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Remove the protective cap, install one end of a clear hose onto one FRONT bleeder screw, and Hydraulic Brake direct the other end into a container; then while Systems holding slight pressure on the brake lever, open the bleeder screw and watch for air bubbles.
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING/REPLACING PADS C. Remove the protective cap, install one end of a clear hose onto the rear bleeder screw, and direct the other end into a container; then while The clearance between the brake pads and brake discs holding slight pressure on the brake pedal, open is adjusted automatically as the brake pads wear.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover.
  • Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the drive- shaft. Secure the drive face with a washer and nut (coated with red Loctite #271). Tighten the nut to 147 ft-lb.

  • Page 22: Table Of Contents

    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 ............3-3 450 Table of Contents ..........3-6 www.mymowerparts.com Manual Table of Contents...

  • Page 23: Engine/Transmission

    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 VALVES AND GUIDES which show a progression for the complete servicing Valve Face Diameter (intake) 35.0 mm of the Arctic Cat ATV engine/transmission.

  • Page 24: Troubleshooting

    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 crankshaft) Condition Remedy 1. Main bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace crankshaft assembly 3.
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2. Valve springs weak 2. Replace springs 3. Valve timing incorrect 3. Re-time valve gear 4. Piston ring(s) - cylinder worn 4.

  • Page 27: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the left footwell, footrest, and footwell support assembly; then drain the coolant into a Table of Contents suitable container. (450) Removing Engine/Transmission......3-6 Top-Side Components..........3-8 Removing Top-Side Components ......3-8 Servicing Top-Side Components......
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI519A FI533A 8. Disconnect the crankcase breather hose from the 11. Remove the screens securing throttle arm cover to air filter housing and remove the air filter assem- the throttle body; then loosen the throttle cable bly.

  • Page 29: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the cap screws securing the two tappet covers. Remove the two tappet covers. Account for the O-rings. FI537 15. Remove the four cap screws securing the rear driveline to the output drive flange.
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Care should be taken not to drop the C-ring down into the crankcase. FI607A MD1131 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cylinder head.
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI616 CD211 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. FI617 FI623A  AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section.

  • Page 32: Servicing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the two nuts securing the right side of the NOTE: It is advisable to remove the opposite-side cylinder to the right-side crankcase half. circlip prior to using the puller.
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the cylinder head cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head cover in a figure eight motion. Inspect the sealing sur- face for any indication of high spots.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Valve Face/Seat Width Servicing Valves/Valve Guides/Valve Seats 1. Using a calipers, measure the width of the valve face. If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1011A CC400D 4. Place a spring retainer over the valve springs; then 2. Remove each ring by working it toward the top of using the valve spring compressor, compress the the piston while rotating it out of the groove.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement does not meet specifications, the piston pin must be replaced.
  • Page 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 3. Maximum distortion must not exceed specifica- tions.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Cam Chain Guide Measuring Camshaft Runout 1. Inspect cam chain guide for cuts, tears, breaks, or NOTE: If the camshaft is out of tolerance, it must chips. be replaced.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC005D CC287D 2. Place a strip of plasti-gauge in each of the cam- NOTE: If the journals are worn, replace the cam- shaft lands in the cylinder head. shaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head.

  • Page 40: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION Installing Top-Side The cylinder should slide on easily. Do not force the Components cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. A. Piston B. Cylinder 1.
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI621 CD383 6. Place a new gasket into position on the cylinder. 12. With the alignment pin installed in the camshaft Place the alignment pins into position; then place and the cam lobes directed down (toward the pis-...
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole. MD1359 14. Place the C-ring into position in its groove in the cylinder head.

  • Page 43: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 19. Rotate the crankshaft until the first cap screw 27. Adjust valve/tappet clearance (see Section 2). (from step 17) securing the sprocket to the cam- 28. Place the two tappet covers with O-rings into posi- shaft can be addressed;...
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the water pump drive gear; then remove the speed sensor housing assembly. Account for two alignment pins, a gasket, and two seal wash- ers. FI538 2. Remove the water pump housing assembly noting the location of the longer cap screw.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Using the Magneto Rotor Remover Set, break the rotor/flywheel loose from the crankshaft; then remove the puller and crankshaft protector and remove the rotor/flywheel. FI559 12. Remove the shift detent cam arm and spring.

  • Page 46: Servicing Left-Side Components

    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 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REPLACING STATOR/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft posi- tion sensor, and one cap screw from the harness hold-down.

  • Page 48: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI593 MD1122 2. Install the starter motor and tighten the two cap screws securely. 3. Install the shift detent cam making sure the washer is installed. FI594 2. Clean the bearing bores in the housing and inspect closely for cracks or shiny areas indicating bearing movement.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI555A FI547 7. Install the starter clutch gear onto the crankshaft; 11. Install two alignment pins and a gasket on the then install the rotor/flywheel key in the crank- magneto cover; then install the water pump hous- shaft.

  • Page 50: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely. Right-Side Components  AT THIS POINT To service center crankcase components only, pro- ceed to Removing Right-Side Components.
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1036 MD1068 5. Using a 6 mm cap screw threaded into the fixed 8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake driven face, spread the driven pulley by turning the plate.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes. FI630 14. Remove the oil pump drive gear cap screw. MD1286 12.

  • Page 53: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. MD1020 ...

  • Page 54: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Check that the clutch shoe can only be rotated counterclockwise in respect to the clutch housing. If the clutch shoe locks up or turns in both direc- tions, the one-way clutch must be replaced.
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the strainer cap into position on the crank- case making sure the O-ring is properly installed and secure with the four cap screws; then tighten the oil drain plug to 16 ft-lb.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. MD1342 12. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loc- tite #271).

  • Page 57: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC137 KC141 NOTE: The arrows on the V-belt should point in NOTE: At this point, the cap screw can be direction of engine rotation. removed from the driven pulley face.

  • Page 58: Crankcase Separator/Crankshaft Remover

    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 NOTE: To aid in installing, it is recommended that...
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI659A FI646 FI661A FI653A 2. Remove the reverse idler assembly (B). Account 4. Remove the gear shift shaft (F) noting the inner for and note the location of the inner bushing (1), and outer washers.

  • Page 60: Servicing Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECONDARY GEARS 6. Remove the crank balancer driven gear (G) and account for a key; then remove the crankshaft bal- ancer shaft. NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur.
  • Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Clean the secondary driven bevel gear teeth of old If tooth contact pattern is comparable to an incorrect oil and grease residue. pattern, correct tooth contact according to the follow- ing chart.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod Measuring Crankshaft (Big End Side-to-Side) (Web-to-Web) 1. Push the lower end of the connecting rod to one 1. Using a calipers, measure the distance from the side of the crankshaft journal.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the splined washer; then remove the cir- clip securing the high-low sliding dog. Remove the sliding dog. FI664 2. Remove the splined washer; then remove the reverse driven gear along with the bearing and bushing.
  • Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI671 FI668A 3. Install the low driven bushing (10), bearing (9) ASSEMBLING and gear (11) on the countershaft; then install splined washer (12). 1. With the high driven washer (1) on the counter- shaft, install the high driven gear bushing (3), bearings (2), and gear (4) on the countershaft;...

  • Page 65: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Crankcase Half NOTE: For ease of assembly, install components on the right-side crankcase half. NOTE: If the output shaft was removed, make sure that the proper shim is installed.
  • Page 66 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 until the oil begins to smoke; then slide the crank- shaft assembly into place.

  • Page 67: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses; then install the center carrier bearing alignment C-ring.

  • Page 68: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI639B CC871 5. In a crisscross pattern, tighten the 8 mm cap NOTE: Be sure to apply sealant to the inside screws until the halves are correctly joined; then radius of all cap screw locations and the entire tighten to 21 ft-lb.

  • Page 69: Install The Spark Plug

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. From the top side, install the ECT sensor connec- tor (C), fuel injector connector (D), MAP sensor connector (E), ISC connector (F), and the TPS connector (G). FI530B FI522A 10.
  • Page 70 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 Electronic Fuel Injection .......... 4-2 Throttle Body............4-2 Fuel Injector ............4-4 Throttle Cable Free-Play ......... 4-4 Engine RPM (Idle)........... 4-5 Gas Tank ..............

  • Page 71: Tachometer

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The MIL is a small wrench icon, and the codes are four digits preceded by a letter C (chas- Fuel/Lubrication/ sis) or P (power train). Cooling 4. Check the air filter and air intake system for con- tamination or restrictions.
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the screws securing the throttle actuator NOTE: None of the EFI components housed in cover to the throttle body; then remove the cover. the throttle body are serviceable and must be...
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI528A FI528B 6. Install the storage compartment, storage compart- 5. Remove the fuel injector from the intake pipe. ment cover, and seat making sure the seat locks 6. Place the new fuel injector into the intake pipe;...
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Clean all gas tank components with parts-cleaning solvent. 2. Inspect all hoses for cracks or leaks. 3. Inspect tank cap and tank for leaks, holes, and damaged threads. 4. Remove the fuel level sensor/fuel pump assembly and inspect the fuel level sensor and fuel screen.
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the cap screws and nuts securing the radi- ator to the frame. 6. Disconnect the fan wiring from the main wiring harness; then remove the radiator/fan assembly and account for the grommets and collars.
  • Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the front bumper and front fender panel. 2. Remove the fan assembly from the radiator. 5. Install the front rack. Installing 6. Fill the cooling system with the recommended 1.
  • Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing 2. Disconnect the gasline hose from the body; then install a suitable pressure gauge. 1. Using a new gasket, install the two alignment pins and gasket onto the magneto cover; then install the...
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING B. Engage the tabs (C) of the fuel level sensor into the mounting slot (B) and press toward the bot- tom of the fuel pump to latch in place; then con- ...
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. TPS out of adjustment 1.
  • Page 80 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 Specifications ............5-2 Battery..............5-2 RPM Limiter............. 5-3 Testing Electrical Components ........ 5-3 Accessory Receptacle/Connector ......5-4 Brakelight Switch (Auxiliary)........

  • Page 81: Timing Light

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System Battery This section has been organized into sub-sections After being in service, batteries require regular clean- which show procedures for the complete servicing of ing and recharging in order to deliver peak perfor- the Arctic Cat ATV electrical system.

  • Page 82: Rpm Limiter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. If the meter reads less than specified voltage, 11. Connect the battery cables (positive cable first); charge the battery using the following guidelines. then install the battery hold-down. A. When using an automatic battery charger, CAUTION always follow the charger manufacturer’s...
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the Accessory switch/component, the connector, and the switch Receptacle/Connector wiring harness for resistance. RESISTANCE (Switch Connector) 1.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine Coolant Temperature (ECT) Sensor 1. Connect the meter leads (selector in OHMS posi- tion) to the sensor terminals. 2. Suspend the sensor and a thermometer in a con- tainer of cooking oil; then heat the oil.
  • Page 85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows no battery voltage, troubleshoot the battery, switches, distribution module, or the main wiring harness. FUSES NOTE: To remove a fuse, compress the locking tabs on either side of the fuse case and lift out.
  • Page 86 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Primary Winding PEAK VOLTAGE 1. Connect the red tester lead to either terminal; then NOTE: All of the peak voltage tests should be connect the black tester lead to the other terminal.
  • Page 87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Speed Sensor NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position.
  • Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (HI Beam) NOTE: If the meter shows no battery voltage, troubleshoot the battery or the main wiring har- 1. Set the meter selector to the OHMS position. ness. 2. Connect the red tester lead to the yellow wire; then RESISTANCE connect the black tester lead to the gray wire.
  • Page 89 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. With the switch in the RUN position, the meter 1. Set the meter selector to the DC Voltage position. must show less than 1 ohm. 2. Connect the black tester lead to the black wire.
  • Page 90 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Select Differential Lock on the front drive actuator 1. Set the meter selector to the AC Voltage position. switch; then connect the red tester lead to the 2. Test between the three yellow wires for a total of white/orange wire in the supply harness.

  • Page 91: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the red tester lead to the positive battery terminal; then connect the black tester lead to the Starter Motor starter cable connection on the starter relay. The meter must show battery voltage.
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the two cap screws securing the starter to the crankcase; then remove the starter. Account for Headlights the wiring forms and an O-ring. INSTALLING 1. Apply a small amount of grease to the O-ring seal on The connectors are the four 2-prong ones plugged into the starter;...
  • Page 93 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Make sure the brake lever (hand) and brake pedal (auxiliary) are properly adjusted for Code Description Problem this procedure. C0063 Tilt Sensor Circuit High 1. Set the meter selector to the DC Voltage position.
  • Page 94 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 OUTPUT VOLTAGE Tilt Sensor NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected. ! WARNING 1. Connect the three-wire plug to the sensor; then...
  • Page 95 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up. PR538A NOTE: If the meter does not read as specified, check for poor connections at the ECU or CD705A open/broken wires in the wiring harness.
  • Page 96 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR546A FI672 8. Select the DC Voltage position on the meter and 3. Using a multimeter, connect the black tester lead turn the ignition switch to the ON position. The to the black socket (GND) on the analyzer and the meter should read approximately 4.5 DC volt with...

  • Page 97: Spark Plug Fouled

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. ECU defective 4.
  • Page 98 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates) Condition Remedy 1. Charging rate too low - too high 1. Replace battery 2. Battery electrolyte insufficient 2.
  • Page 99 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/Electronic Differential Lock ..6-2 Front Differential ............6-3 Drive Axles ............6-16 Rear Gear Case ............ 6-21 Hub................
  • Page 100 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Special tools are available from the Arctic Cat Service Parts Department. Drive System Front Drive NOTE: Some photographs and illustrations used Actuator/Electronic in this section are used for clarity purposes only Differential Lock and are not designed to depict actual conditions.
  • Page 101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Loosen but do not remove the mounting cap screw at the front of the actuator; then slide the actuator to the rear enough to clear the slotted mounting tab and the selector shaft.
  • Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the drain plug and drain the gear lubricant into a drain pan; then reinstall the plug and tighten to 45 in.-lb. AF895D 9. Remove the tie rod lock nuts.
  • Page 103 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX151 AF899D 16. Remove the inner fender panels. 12. Support the axle to not allow it to drop or hang. 17. Using a T-30 torx wrench, remove the three screws CAUTION securing the front drive actuator to the gear case;...
  • Page 104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD016 CD102 20. Free the differential assembly from the frame 2. Using a rubber mallet, remove the housing. mountings; then shift the differential assembly for- Account for a gasket. Remove the fork, collar, and ward enough to disengage the front driveshaft spring.
  • Page 105 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 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Place the pinion housing with new gasket onto the gear case housing; then secure with the existing cap screws. Tighten to 23 ft-lb. NOTE: If a new gear case housing is being installed, tighten the cap screws to 25-31 ft-lb.
  • Page 107 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Using a plastic mallet, tap lightly to remove the differential 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 108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If gears are being replaced, use the exist- ing shims. The numbers are scribed onto the gears: the ring gear has the number on the oppo- site side of the gears, and the pinion gear has the number on the end of the pinion gear shaft by the splines.
  • Page 109 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 tighten the bolts to 28 ft-lb. Verify backlash to be within a range of 0.28-0.38 mm (0.011-0.015 in.) and end-play to be within a range of 0.10-0.20 mm (0.004-0.008 in.).
  • Page 110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC892 CD110 6. Install the shift fork assembly making sure the fork 8. Install the proper shim onto the ring gear spider leg is facing upward. Apply a small amount of oil assembly making sure the chamfer side of the to the gasket;...
  • Page 111 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF266A CC885 2. Using a propane torch, heat the area surrounding the needle bearing to soften the Loctite. CF267A 10. Apply a liberal amount of grease to the O-ring; then install it on the assembled cover assembly...
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC888 CC891 2. Using a suitable driver, install the needle bearing 5. Install the pinion housing. into the gear case housing making sure the bearing Removing/Installing Axle Seal is seated.
  • Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC901 CD859 2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid NOTE: Prior to installing the seal, apply High Per- gear lubricant into the differential and install the formance #2 Molybdenum Disulphide Grease to fill plug.
  • Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the ATV from the support stand. Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING AF897D Make sure the ATV is solidly supported on the support 8.
  • Page 115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF935 CD020 2. Wipe away excess grease to access the retaining REMOVING FRONT DRIVE AXLE ring. Using an awl, remove the circlip. NOTE: For removing a front drive axle, see Front Differential in this section.
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD022 ATV-1052 5. Inspect the splines of the shaft, the bearing ring, NOTE: Grease Pack contains 120 grams of and the housing for damage. grease. The inside joint (double-offset) requires approximately 70-90 grams of grease and the out- NOTE: If any damage is apparent to the splines,...
  • Page 117 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 side without splines facing toward the small clamp of the 1. Install the inner boot with the small clamp making inner boot or severe damage will result.
  • Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steer- ing knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tightened to 50 ft-lb.
  • Page 119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Rear Gear Case Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the cotter pin from the nut. REMOVING NOTE: During assembly, new cotter pins should 1.
  • Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Secure the brake disc to the hub with the four cap screws coated with blue Loctite #243. Tighten to 15 ft-lb. 2. Apply grease to the splines in the hub.
  • Page 121 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV and do not reuse brake fluid. NOTE: Whenever brake components removed, disassembled, or repaired where brake...
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2. Inspect the brake pads for damage and excessive wear.
  • Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR239C PR239 5. Making sure brake fluid does not contact the brake 6. Place the brake caliper assembly into position and pads, compress the caliper holder toward the cali- secure with new “patch-lock” cap screws. Tighten per and install the inner brake pad;...
  • Page 124 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 125 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 ............ 7-7 Troubleshooting ............7-8 www.mymowerparts.com...

  • Page 126: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the two cap screws and nut securing each rear shock absorber to the frame and lower A-arm. Suspension Account for bushings and sleeves from each. The following suspension system components should be inspected periodically to ensure proper operation.

  • Page 127: Front A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION Do not tighten the nuts beyond the recommended specification or the shock eyelet or mount WILL be damaged. 3. Remove the ATV from the support stand. Front A-Arms REMOVING AF618D 7.
  • Page 128 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 CLEANING AND INSPECTING shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet.

  • Page 129: Rear A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: During assembly, new cotter pins should be installed. CD008 13. Install the wheel and tighten to 40 ft-lb. 14. Remove the ATV from the support stand. AF618D 8. Apply grease to the hub and drive axle splines;...
  • Page 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF934 PR290 8. Slide the hub out of the knuckle and set aside. 5. Secure the hub assembly with the nut. Tighten only until snug. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms.

  • Page 131: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Secure the shock absorber to the lower A-arm with 2. Remove the wheels. a cap screw and new lock nut. Tighten to 20 ft-lb. NOTE: Keep left-side and right-side wheels sepa- 11.

  • Page 132: 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 133 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 ............8-4 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-6 Front Rack ............... 8-8 Front Bumper Assembly .......... 8-8 Front Body Panel/Side Panels.........

  • Page 134: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame The following steering components should be inspected periodically to ensure safe and proper opera- tion. 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 135 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect all welded areas for cracks or deteriora- tion. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 6. Inspect the bearing halves, bearing caps, and bear- ing housings for cracks or wear.

  • Page 136: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF778D KC309A 4. Install the front wheels and tighten to 40 ft-lb 2. Grasp the end and remove the cap screw, plug, and using a crisscross pattern. end cap. 5. Lower the ATV and place the handlebar and caps INSPECTING into position on the steering post;...
  • Page 137 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ASSEMBLING AND INSTALLING 4. Remove the brake caliper. 5. Remove the hub assembly. 1. Install the bearing; then install the snap ring mak- ing sure it seats into the knuckle.

  • Page 138: Measuring/Adjusting Toe-In

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring/ Adjusting Toe-In 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.
  • Page 139 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Measure the distance from the inside of each front rim to the lower frame tube. AF778D NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be AF785D taken not to disturb the handlebar position.

  • Page 140: Front Rack

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all bumper components with parts-cleaning solvent. 2. Inspect all welds for cracking or bending.
  • Page 141 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: It may be necessary to rotate the body panel to the right to align the opening with the han- dlebar. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 142: Footrests

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 6. Install the shift lever spring, shift lever, and pivot axle; then tighten the axle nut securely. 1. Secure the footrests to the frame with four cap screws and two flange nuts; then tighten the 8 mm hardware to 20 ft-lb and the 10 mm hardware to 40 ft-lb.

  • Page 143: 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- 1. Clean all rear body panel components with warm fler back and forth and listening for rattles or loose soap and water.

  • Page 144: Taillight Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 6. Place the seat into position making sure it locks securely. 1. Place the assembly into position on the frame and secure with torx-head cap screws and any washers.

  • Page 145: 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 146 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 ............9-3 Shift Lever ............... 9-4 Speedometer/Tachometer/LCD....... 9-4 www.mymowerparts.com Manual Table of Contents...

  • Page 147: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the Hand Brake Lever/ pivot pin hole in the housing; then lay it aside Master Cylinder leaving the switch and wiring harness connected.

  • Page 148: Throttle Control

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING Throttle Control 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar.

  • Page 149: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 2. Remove two cap screws, two self-tapping screws, and three nylon ties securing the left-side splash panel and remove the panel. 1. Place the return spring into the throttle control;...

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