Arctic Cat DVX 400 2006 Manual
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Arctic Cat DVX 400 2006 Manual

Arctic Cat DVX 400 2006 Manual

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2006 Arctic Cat DVX 400
ATV model. The manual is designed to aid service personnel in service-oriented applications and may be used as
a textbook for service training.
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. A troubleshooting section is also included in this manual.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying this 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
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.
© 2006 Arctic Cat Inc.
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the tech-
Back to TOC
NOTE: identifies
April 2006

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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: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Click on the red text to go. Foreward Section General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission 2006 2006 Fuel/Lubrication/Cooling Electrical System DVX 400 Drive System Suspension Service Service Manual 8.

  • Page 3: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........1-3 Genuine Parts ............1-4 Preparation For Storage.......... 1-4 Preparation After Storage........

  • Page 4: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* CARBURETOR CHASSIS Type Mikuni BSR37 Dry Weight (approx) 169 kg (373 lb) Main Jet Length (overall) 183 cm (72 in.) Pilot Jet 22.5 Height (overall) 116 cm (45.7 in.)

  • Page 5: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Break-In Procedure Do not attempt sudden stops or put the ATV into a situation where a sudden stop will be required until the brake pads are properly burnished.

  • Page 6: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision- made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the cor- rect part number, quantity, and description.

  • Page 7: Preparation After Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Tighten all nuts, bolts, cap screws, and screws. 3. Check all control wires and cables for signs of Make sure rivets holding components together wear or fraying. Replace if necessary.
  • Page 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Cleaner .............. 2-4 Valve/Tappet Clearance ......... 2-6 Tappet Shim Selection Table (Exhaust) ....2-9 Tappet Shim Selection Table (Intake) ....

  • Page 9: Periodic Maintenance Chart

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

  • Page 10: Lubrication Points

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 This maintenance-free battery requires periodic charging to prevent sulfiding. If the ATV will be idle Lubrication Points for extended periods of time, either run the engine or trickle charge every 30 days. If the battery com- pletely discharges, permanent damage will occur requiring replacement.

  • Page 11: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Air Cleaner The air filter inside the air cleaner must be kept clean to provide good engine power and gas mileage. If the ATV is used under normal conditions, service the filter at the intervals specified.
  • Page 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP013 SP119 5. Fill a wash pan larger than the filter with a REMOVING non-flammable cleaning solvent; then dip the filter in the solvent and wash it. 1. Remove the seat.

  • Page 13: Valve/Tappet Clearance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING SP014A 7. Install the seat making sure the seat is properly secured. 10. Clamp Valve/Tappet 1. Air Cleaner Assy 11. Clamp Clearance 2. Filter 12. Flame Trap 3. Holder 13.
  • Page 14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The camshaft lobes must be in position (A) in order to check valve/tappet clearance. SP121 NOTE: The valve/tappet clearance specification is different for intake and exhaust valves. The SP124 clearance should only be checked when the 6.
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the selected shim at the valve stem with the numbers facing the tappet. Be sure to mea- sure the shim with a micrometer to ensure it is the proper size. Refer to the tappet shim selec- tion table for details.
  • Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com ATV2152 Next Back Back to TOC Back to Section TOC...
  • Page 17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com ATV2153 Next Back 2-10 Back to TOC Back to Section TOC...

  • Page 18: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Testing Engine Spark Plug Compression A light brown insulator indicates that the plug is correct. A white or dark insulator indicates that the To test engine compression, use the following pro- engine may need to be serviced or the carburetor cedure.

  • Page 19: Muffler/Spark Arrester

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Muffler/Spark Arrester Gas/Vent Hoses The muffler has a spark arrester which must be peri- Replace the gas hose every two years. Damage from odically cleaned. At the intervals shown in the Peri- aging may not always be visible.

  • Page 20: Adjusting Engine Rpm (Idle)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is necessary. To adjust idle RPM, use the following procedure. 1. With the transmission in neutral, start the engine and warm it up to normal operating temperature.
  • Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION If the oil filter element is inserted backwards, engine damage will occur due to lack of oil flow. 7. Place the filter cover in position with the trian- gle mark up and secure with the cap screws.

  • Page 22: Adjusting Clutch Lever Cable

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjusting Clutch Lever Steering Components Cable The following steering components should be inspected periodically to ensure safe and proper To adjust the cable, use the following procedure. operation. 1. Pull rubber protective boot away from the cable A.

  • Page 23: Nuts/Bolts/Cap Screws

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Nuts/Bolts/Cap Screws Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications.

  • Page 24: Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Make vertical marks which intersect the hori- C. Reverse switch — reverse indicator light illu- zontal marks on the aiming surface directly in minates. front of the headlights. D. Hi/Lo switch — headlight beam bright and 5.

  • Page 25: Frame/Welds

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the rear brake reservoir cap. If the level NOTE: Debris between the cooling fins of the in the reservoir is not above the mark, add DOT radiator can reduce cooling capability. Using a 4 brake fluid.
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 D. Repeat step C until no air bubbles are observed in the bleeder line. Close the bleeder screw and tighten. E. Perform steps B,C, and D on the other FRONT bleeder screw repeating step C until no air bubbles are observed in the bleeder line.
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Measure the thickness of each brake pad. SP128 NOTE: Make sure the detent of the brake pad is AF739DB fitted to the recess on the brake caliper bracket. 3. If thickness of any brake pad is less than 2.0 mm (0.078 in.), all brake pads must be replaced.
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MEASURING/REPLACING REAR 5. Using a calipers, measure the thickness of each brake pad. BRAKE PADS 6. If the thickness of any brake pad is less than 2.0 1. Release the parking brake, if applied; then mm (0.078 in.), all brake pads must be replaced.

  • Page 29: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP130 SP130 2. Loosen the parking brake cable adjuster (3) and NOTE: Check that rear wheels turn freely when turn the adjuster (4) to achieve a cable length of the parking brake is released and that they lock 47-51 mm (1.9-2.0 in.) at (A).

  • Page 30: Coolant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Coolant Drive Chain The cooling system capacity is approximately 1.2 L INSPECTING (1.3 U.S. qt). The cooling system should be inspected daily for leakage and damage. Also, the To properly check the drive chain for defects, sup- coolant level should be checked periodically.
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2156 ATV2157 2. Tighten the four cap screws to specifications ADJUSTING (see Section 10) and recheck the chain tension. To adjust the drive chain, use the following proce- REPLACING dure.
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Install a new driven sprocket; then apply red Loctite #271 to the sprocket mounting cap screws and tighten to specifications (see Section 10). 10. Install a new chain and adjust (see Adjusting in this sub-section).
  • Page 33 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 Table of Contents (Removing/Disassembling/ Assembling/Installing) .......... 3-4 Table of Contents (Servicing Components)... 3-16 www.mymowerparts.com Back to TOC...
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission This section has been organized into sub-sections which show a progression for the complete servic- ing of the Arctic Cat ATV engine/transmission. To service the center crankcase halves, the engine/transmission must be removed from the frame.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CYLINDER, PISTON, AND RINGS Specifications Piston Skirt/Cylinder Clearance (max) 0.12 mm (0.0047 in.) Cylinder Bore (max) 90.015 mm (3.544 in.) Piston Diameter 89.965-89.950 mm 15 mm (0.60 in.) from Skirt End (3.5419-3.5425 in.)
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the negative cable from the battery; then remove the positive cable. Remove the bat- Table of Contents tery hold-down; then remove the battery. (Removing/Disassembling/Assembling/ Installing) ! CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing.
  • Page 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP142 SP139 12. Remove the carburetor leaving the throttle cable 8. Remove the gas tank (see Section 4). and the choke cable attached; then secure the carburetor out of the way sufficiently to enable 9.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP149 SP145 20. Remove the thermostat cover (4) and thermo- 17. Remove the reverse gear selector cable bracket stat; then remove the exhaust pipe (5). (5); then disconnect the reverse gear selector cable (6).

  • Page 39: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Left-Side Components A. Cover B. Drive Gear C. Rotor/Flywheel D. Neutral Switch 1. Remove the cap screws securing the starter drive cover; then remove the cover and drive gear. Account for two thrust washers and the large O-ring.

  • Page 40: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the starter driven gear (2), two align- 7. Remove the Allen-head cap screws securing the ment pins (3), and the cover gasket (4). Account neutral switch housing (1); then remove the for two thrust washers from the driven gear.

  • Page 41: Removing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Right-Side Components A. Clutch Cover B. Clutch Sleeve Hub Assembly C. Primary Driven Gear Assembly D. Oil Pump Idler Gear and Driven Gear E. Oil Pump SP157A F. Shift Shaft 4.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP161 SP164 SP162 8. Remove the cam chain tensioner (4) and the cam chain (5); then remove the oil pipe (6). SP165 10. Remove the circlip (2) from the left side of the shift shaft;...
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP171 15. Holding the rotor/flywheel with a 27 mm offset SP168 wrench, remove the rotor nut; then remove the 12. Remove the shift cam driven gear bolt. rotor/flywheel using the magneto rotor remover.

  • Page 44: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Top-Side Components A. Valve Cover B. Cylinder Head C. Cylinder NOTE: Remove the spark plug, timing inspection plug (1), and the alternator cover cap (2); then SP174 using a socket wrench, rotate the camshaft to 17.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP179 SP182 NOTE: Use caution not to drop the alignment pins or the camshaft drive chain into the crank- case. 4. Remove the four alignment pins (5); then remove the intake camshaft (6) keeping tension on the chain.

  • Page 46: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Place a clean rag over the cylinder to pre- vent the piston-pin circlip from dropping into the crankcase. 9. Using an awl, remove one piston-pin circlip. 10. Push out the piston pin; then remove the piston.

  • Page 47: Disassembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP188 SP191 2. Remove the reverse idler gear and shaft; then remove the countershaft assembly (1) and drive- shaft assembly (2). SP189 2. Install Crankcase Separator/Crankshaft Remover (p/n 0444-009) on the right-side...

  • Page 48: Servicing Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Top-Side Components NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, SP194 valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP198 SP203 3. Using a valve spring compressor and special 5. Remove the oil seal with a needle-nose pliers; adapter to compress the valve springs, remove then remove the valve spring seat.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV1082A ATV-1082 3. Rotate the valve in the V blocks. 2. Maximum runout must not exceed specifica- tions. 4. Maximum runout must not exceed specifica- tions. Measuring Valve Stem Outside Diameter...
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. If a valve guide is out of tolerance, it must be replaced. Replacing Valve Guide NOTE: If a valve guide is worn or damaged, it must be replaced. 1. If a valve guide needs replacing, insert a valve guide remover into the valve seat side of the valve guide.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Grinding Valve Seats 2. Lubricate each valve stem with light oil; then apply a small amount of valve lapping com- pound to the entire seating face of each valve. NOTE: If the valve seat is beyond servicing, the cylinder head must be replaced.

  • Page 53: Piston Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PISTON ASSEMBLY NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for NOTE: Whenever a piston, rings, or pin are out proper installation.

  • Page 54: Cylinder/Cylinder Head Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning/Inspecting Cylinder Head ! CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combus- tion chamber being careful not to nick, scrape, or damage the combustion chamber or the seal- ing surface.
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuff- ing, warpage, and corrosion. 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Match the width of the plastigauge with the chart found on the plastigauge packaging to determine camshaft to cylinder head journal clearance. ATV1013A 2. The lobe heights must not exceed minimum specifications.

  • Page 57: Servicing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. If damaged, the camshaft must be replaced. Servicing Left-Side Components STARTER CLUTCH To replace the starter clutch, use the following pro- cedure. SP208 3. Install the starter driven gear (1) into the starter 1.

  • Page 58: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring) CC245D 3. Maximum driven plate warpage must not NOTE: Prior to inspecting and measuring com- exceed specifications.

  • Page 59: Crank Balancer Driven Gear

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP211A 5. Pin 1. Nut 6. Spring NOTE: Do not attempt to disassemble the oil 2. Washer 7. Bearing pump housing assembly. It is serviceable only as a 3. Driven Gear 8.

  • Page 60: Servicing Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. CRANKCASE (Cleaning and Inspecting) SP217 1. Remove the oil sump filter and clean using com- 4.

  • Page 61: Crankshaft Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC290D SP219 2. Maximum diameter must not exceed specifica- 6. Install the new bearing using the bearing tions. installer; then apply a small amount of red Loc- tite #271 to the bearing retainer screws and Measuring Connecting Rod tighten securely.

  • Page 62: Driveshaft

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. 2. Acceptable width range must be within specifi- cations.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling 16. Gear, 4th Driven 31. Chain Assy 1. Countershaft 17. Gear, 5th Driven 32. Joint Set 2. Gear, 2nd Drive 18. Gear, Reverse 33. Retainer 16. Gear, 4th Driven 31.
  • Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD366 CC208D 5. Install the 5th driven gear onto the driveshaft. 6. In order, install the reverse driven bushing, reverse driven gear, washer, and circlip onto the driveshaft. Make sure the oil hole in the reverse driven bushing aligns with the hole in the drive- shaft.

  • Page 65: Countershaft

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC221D CC203D 3. Remove the 4th drive washer and 4th drive cir- clip from the countershaft. CC222D 9. Install the 1st driven washer (left side) on the driveshaft. CC201D NOTE: The driveshaft is now completely assem- bled for installation.

  • Page 66: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC199D CC201D 6. Remove the remaining 5th drive washer from 5. Install the 2nd drive gear and washer onto the the countershaft. countershaft. Assembling 1. Install the first 5th drive washer onto the coun- tershaft.

  • Page 67: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Check to be sure that the gears all engage normally; then shift the transmission into neutral. 7. Verify that the two crankcase half alignment pins (1) are in place.

  • Page 68: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP228 CC095D 5. In a crisscross/case-to-case pattern, tighten the NOTE: Rotate the shafts back and forth to cap screws (from steps 3-4) until the halves are ensure no binding or sticking occurs.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Align the keyway with the key and install the rotor/flywheel; then using an offset 27 mm wrench, hold the flywheel and tighten the nut to specifications. SP251 5. Apply engine oil to the threads; then install the...
  • Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP238A SP237 10. Apply red Loctite #271 to the oil pump mount- 8. Install each pawl lifter into the shift cam driven ing screws and tighten securely; then install the...
  • Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 15. Bend the washer over securely engaging the flat of the nut. SP243A 13. Install the spacer (3), primary driven gear assembly (1), washer (2), clutch sleeve hub (4), lock washer (14), and clutch sleeve hub nut (13) SP246 on the driveshaft.

  • Page 72: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 18. Install the alignment pins (1) and a new gasket (2); then install the clutch cover using a new washer gasket at position (1). Tighten the cap screws securely. SP252A 2.
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Install the spacer (3) into the oil ring groove; 4. Place a clean rag over the cylinder base to pre- then install the two side rails (4). vent the piston-pin circlip from dropping into the crankcase;...
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder Head D. Camshafts E. Valve Cover F. Cam Chain Tensioner NOTE: Steps 1-7 of the preceding sub-section must precede this procedure. 8. Install the cylinder head on the cylinder.
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP263 12. Apply moybdenum oil solution to the camshaft journals, camshaft lobes, and the camshaft jour- nal holders; then place each camshaft into the correct position. ATV2177 16. Install the alignment pins (1) and cam chain guide;...

  • Page 76: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Do not apply engine oil to rubber cushion (2). SP267 19. Install a new gasket and the cam chain tensioner assembly into the cylinder making sure the UP stamp is directed towards the cylinder head.
  • Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2178 SP273 3. Tighten the engine mounting fasteners to the 6. Install the engine coolant hose; then install the specifications. spacer (1) with O-ring to the engine oil outlet pipe and tighten the cap screws (2) securely.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the carburetor and tighten the clamps securely. 12. Install the spark plug cap, engine sprocket cover, oil drain, tank, and breather hose; then install the gas tank and body.
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-3 Cleaning and Inspecting Carburetor......4-6 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle)........... 4-7 Gas Tank ..............

  • Page 80: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor Specifications ITEM Type Mikuni BSR37 Main Jet Pilot Jet 22.5 Pilot Screw (turns) 1 1/2 Needle Jet P-OM Jet Needle 5E26-1 Idle RPM 1250-1350 Starter Jet Float Arm Height 13 mm (0.5 in.)

  • Page 81: Carburetor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor ! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- ing, open flames, etc., in the area.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP286 SP283 NOTE: Note the locations of the jets, pilot screw, 3. Remove the two screws securing the primer and holder for disassembling procedures. housing cover. Account for the primer dia- phragm assembly (11) and spring.
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Check float arm height (A) by placing the carburetor on its side w/float contacting the nee- dle; then measure with a caliper the height when the float arm is in contact with the needle valve.

  • Page 84: Cleaning And Inspecting Carburetor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Place all metallic components in a wire basket and submerge in carburetor cleaner. 2. Soak for 30 minutes; then rinse with fresh parts-cleaning solvent. 3. Wash all non-metallic components with soap and water.

  • Page 85: Engine Rpm (Idle)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.

  • Page 86: Fuel Valve

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel Valve The fuel valve is on the gas tank. There are three positions: ON, RES (reserve), and PRI (primer). SP289 6. Remove the gas tank. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 87: Gas/Vent Hoses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the two nuts securing the fuel valve; then remove the valve. Account for the gasket. Oil Filter/Oil Pump 3. Inspect the gasket and fuel valve/tank mating surfaces for damage or deterioration.

  • Page 88: Testing Oil Pump Pressure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ASSEMBLING/INSTALLING Oil Tank 1. Place the rotors into the pump housing making sure the alignment pin is in the groove of the rotor. REMOVING 2. Install the oil pump into the engine (see Section 3 - Right-Side Components).

  • Page 89: Liquid Cooling System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 6. Start the engine and check for coolant or oil leaks; then recheck the proper coolant and oil 1. Ensure that the tank mounting isolators are ser- levels. See Section 2.

  • Page 90: Radiator

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the radiator with cushions and spacers into position on the frame; then install the cap screws Radiator and nuts. Tighten securely. 3. Install the upper and lower coolant hoses; then secure with hose clamps.

  • Page 91: Fan

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. The thermostat should start to open at 75°C REMOVING (167°F). 1. Drain the engine coolant and engine oil; then D. If the thermostat does not open, it must be disconnect the radiator hose.
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP302B 2. Using Seal Removal Tool (p/n 0644-072), remove the shaft seal and the oil seal. SP298 4. Remove the water pump case; then remove the circlip (1), water pump driven gear (2), drive pin (3), and washer (4).
  • Page 93 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the new shaft seal into the housing; then tap it down until it is fully seated. NOTE: A large, deep socket can be used to drive the seal down evenly.

  • Page 94: Engine Coolant Temperature Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine Coolant Cooling Fan Temperature Switch Thermo-Switch REMOVING REMOVING 1. Drain the coolant in the radiator to a point below 1. Drain the coolant in the radiator to a point below the upper temperature switch.
  • Page 95 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Specifications ............5-2 Battery..............5-2 Testing Electrical Components........ 5-3 Brakelight Switch (Front Brake) ....... 5-3 Brakelight Switch (Rear Brake) ....... 5-3 Coolant Temperature and Cooling Fan Switches ..5-3 Fan Motor ..............

  • Page 96: Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 If the battery is discharged, remove the battery from the ATV and charge the battery at the standard Specifications charging rate of 1.5 amps for 5-10 hours. To remove and charge the battery, use the following procedure.

  • Page 97: Testing Electrical Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Testing Electrical Brakelight Switch Components (Rear Brake) The switch connector is the two-prong connector All of the electrical tests should be made using the located along the upper right frame rail.

  • Page 98: Fan Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Suspend the switch and a thermometer in a con- 2. Connect the red tester lead to the orange wire tainer of water; then heat the water. (the black 2-prong at the fan motor); then con- nect the black tester lead to ground.

  • Page 99: Fuse

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the spark plug cap; then connect a new NOTE: If the meter shows no battery voltage, spark plug to the spark plug cap and ground it to troubleshoot the battery, switches, fuse holder, or the cylinder head.

  • Page 100: Indicator Lights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Primary Winding 1. Connect the red tester lead to the terminal (with the wire removed); then connect the black tester lead to ground. 2. The meter reading must be within specification.

  • Page 101: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INDICATOR LIGHTS VOLTAGE 1. Turn the ignition switch to the ON position. 2. Set the meter selector to the OHMS position. NOTE: The ignition switch must be in the ON position, and the test must be performed on the 3.

  • Page 102: Neutral Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot replace Neutral Switch switch/component, the connector, or the switch wiring harness. RESISTANCE (LO Beam) RESISTANCE 1. Set the meter selector to the OHMS position.

  • Page 103: Clutch Lever Position Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Charging Coil - No Load) Clutch Lever Position Switch NOTE: The peak voltage reading adapter must be disconnected for this test. The connector is the black one on the left side near RESISTANCE the voltage regulator.

  • Page 104: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Charging Coil) Starter Motor ! CAUTION Always disconnect the battery when performing resistance tests avoid damaging REMOVING/DISASSEMBLING multimeter. 1. Set the meter selector to OHMS position. 2. Test between the three brown wires for a total of three tests.
  • Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Inspect the left-side cover bushing for wear. 6. Inspect the right-side cover bushing for wear. 7. Inspect the brass commutator end of the arma- ture for any burned spots or damage. If the com- mutator is lightly burned or damaged, the armature must be replaced.
  • Page 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Inspect the armature for shorting using a ASSEMBLING/INSTALLING “growler” and the following procedure. A. Place the armature in the “growler.” B. While holding a metal strip on the armature, rotate the armature an entire revolution.

  • Page 107: Starter Relay

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Secure the positive cable to the starter with the 2. Set the meter selector to DC Voltage position; nut and tighten to specification (see Section 10). then connect the red tester lead to the battery side of the starter relay and the black tester lead 11.

  • Page 108: Regulator/Rectifier

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Disconnect the two-wire plug connector from the appropriate bulb; then select the DC Voltage Regulator/Rectifier position on the multimeter. 3. Connect the black tester lead to the black wire;...

  • Page 109: Throttle Position Sensor (Tps)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Brakelight) 5. With the red tester lead connected to the yel- low-wire pin, connect the black tester lead to the blue-wire pin. NOTE: Perform this test on the main harness side of the connector.

  • Page 110: Ignition Timing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. With the Arctic Cat Engine Tachometer (p/n 0644-275) connected, start the engine and run at Ignition Timing the specified RPM. 3. Ignition timing should be according to specifica- tion.

  • Page 111: Wiring Diagram

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Wiring Diagram Harness (p/n 3509-007) 0741-688 www.mymowerparts.com 5-17 Back Back to TOC Back to Section TOC...

  • Page 112: General Information

    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 General Information..........6-2 Rear Drive Assembly Schematics ......6-2 Rear Drive Axle ............6-3 www.mymowerparts.com Back to TOC...

  • Page 113: Www.mymowerparts.com

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive System Rear Drive Assembly Schematics NOTE: Some photographs and illustrations used in this section are used for clarity purposes only LEFT REAR WHEEL ASSEMBLY and are not designed to depict actual conditions.

  • Page 114: Rear Drive Axle

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Rear Drive Axle REMOVING 1. Secure the ATV on a support stand to elevate the rear wheels. ! WARNING Make sure the ATV is solidly supported on the sup- SP315 port stand to avoid injury.
  • Page 115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the axle housing from the swing arm. CLEANING AND INSPECTING 1. Inspect the sprocket teeth for wear. If they are worn as shown, replace the engine sprocket, rear sprocket, and drive chain as a set.
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install new dust seals and lightly coat with grease. INSTALLING 1. Install the axle housing in the swing arm; then install and finger-tighten the four cap screws. 2. Install the adjuster nut loosley; then install the brake disc applying red Loctite #271 to the Allen-head cap screws.
  • Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2189 SP324 6. Install the outer axle nut (5) and tighten to calcu- 7. Adjust the drive chain (see Section 2); then lated specification. tighten the four cap screws. 8. Install the brake caliper and tighten the mount- ing cap screws to specifications;...
  • Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Front and Rear Suspension Assembly Schematics ............7-2 Front Shock Absorbers..........7-2 Rear Shock Absorber ..........7-4 Swing Arm............... 7-7 Front A-Arms ............7-12 Wheels and Tires ..........

  • Page 119: Front And Rear Suspension Assembly Schematics

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SWING ARM Front and Rear Suspension Assembly Schematics FRONT SUSPENSION 1. Shock Absorber 2. Cap Screw 3. Cap Screw 4. Nut 5. A-Arm 6. A-Arm 7. Bearing 8. Bearing 9. Dust Seal 10.
  • Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Direct the valve stem away from your body. Always wear protective eyewear when releasing high-pres- sure gas. INSTALLING 1. Place the shock absorber spring over the shock absorber, compress the spring, and install the retainer.

  • Page 121: Rear Shock Absorber

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD837A CD833A 3. Tighten the lock nut securely. 2. Turn the adjuster 1 3/4 turns counterclockwise for the “standard” setting. ADJUSTING DAMPING FORCE ! WARNING The compression and rebound damping forces are adjustable.
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the rear shock absorber by lifting up the swing-arm and lowering the shock absorber assembly. SP326 3. Remove the rear arm lower nut and cap screw (3); then remove the shock absorber nuts and cap screws (4-5).
  • Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING ! WARNING 1. Raise the swing-arm and place the shock Do not adjust the spring preload out of the specified absorber in position; then install the upper and range.

  • Page 124: Swing Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP337 SP339 2. Turn the adjuster two full turns counterclock- wise for the “standard” setting. Swing Arm NOTE: Critical torque specifications are located in Section 10. REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the SP340 4.
  • Page 125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP342 SP345 7. Remove the swing-arm pivot nut; then remove the swing-arm pivot shaft and remove the swing arm. SP346 SP343 8. Remove the chain slide. SP347 CLEANING AND INSPECTING...
  • Page 126 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP350 SP348 NOTE: Removed bushings must be replaced with new ones. 5. To inspect front and rear arm bearings, insert the spacer into the bearing; then check for excessive play by moving the bearing up and down. If excessive play is noted, the bearing must be replaced.
  • Page 127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV2194 SP353 ASSEMBLING AND INSTALLING 1. Using a suitable bearing installer, press the new bearing into the swing arm pivot to a depth of 5 mm (0.2 in.); then press the bushing into the swing arm pivot to a depth of 12 mm (0.47 in.).
  • Page 128 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP358A SP361 3. Apply multipurpose grease to the lip of the dust NOTE: The stamped mark of the dust seals must covers; then install the dust covers (1), washers be directed towad the outside of the assemblies.

  • Page 129: Front A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP365 8. Install the rear arm guard and the swing-arm SP367 guard. 5. Remove the hub assembly; then remove the disc cover (2). Front A-Arms NOTE: Critical torque specifications are located in Section 10.
  • Page 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP373 CD877A 10. Using a ball joint remover (8), remove the ball joint from the knuckle (7). SP374 SP371 8. Remove the shock absorber lower mounting cap CLEANING AND INSPECTING screw (4);...
  • Page 131 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The pivots are equipped with roller bear- ings. The bearing rollers may fall out when the spacers are removed. SP376 SP380 5. Check the bearings for excessive wear and replace them if worn.
  • Page 132 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Coat the spacers (2) and the lips of the dust seals (3) with multipurpose grease; then install them in the upper pivot. SP383 SP386 4. Install the bearing spacer (4), dust seals (5), dust covers (6), and washers (7) into the lower arm.
  • Page 133 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP390 SP393 6. Install the arms to the frame with the pivot cap 9. Connect the tie rod ends (11) to the steering screws; then tighten the nuts to specifications.

  • Page 134: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING Wheels and Tires NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. TIRE SIZE 1. Clean the wheels and hubs with parts-cleaning solvent.
  • Page 135 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the tires for damage, wear, or punctures. 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during accel- eration, deceleration, and braking.
  • Page 136 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering Post/Tie Rods ........... 8-2 Measuring/Adjusting Toe-In/Toe-Out ....... 8-7 Body ................ 8-8 www.mymowerparts.com Back to TOC...
  • Page 137 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering Post/ Tie Rods NOTE: Critical torque specifications are located in Section 10. 1. Steering Post 2. Dust Seal SP395 3. Steering Post Holder 3. Disconnect the parking brake cable (3) and 4.
  • Page 138 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP401 SP398 6. Drain the engine oil from the oil tank; then drain the coolant from the radiator. 7. Remove the radiator assembly (1). See Section SP402 SP399 8. Remove the two fasteners; then remove the oil hose protector.
  • Page 139 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Remove the hose and cable guide; then remove the steering post holder. 13. Remove the steering post (9); then remove the dust seals (10), and the steering post holder half (11).
  • Page 140 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 hold- ers for cracks, bends, or wear. 6. Inspect the handlebar clamps for cracks or wear.
  • Page 141 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP416A ATV2202 9. Adjust the handlebar in the holders to align the punch mark (B) with the mating surface of the handlebar holders. Tighten first the forward cap screws (4) to specifications; then tighten the rearward cap screws (5) to specifications.
  • Page 142 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring/Adjusting Toe-In/Toe-Out 1. With the ATV on a level surface, center the han- dlebar for straight ahead using a suitable means of measuring centering; then adjust tire pressure to specifications.
  • Page 143 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to disturb the handlebar position. Body REMOVING 1. Remove the seat; then remove the battery hold-down, battery, and starter relay.
  • Page 144 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Inspect threaded areas of all mounting studs for stripping. 4. Inspect for missing decals. INSTALLING 1. Fit the body over the handlebar and rotate into normal mounting position. 2. Seat the two upper forward support studs and the rear fender support studs into the brackets;...
  • Page 145 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the forward underseat fasteners and tighten the screws only until snug. 5. Install the battery connecting first the positive cable; then the negative cable. 6. Install the battery hold-down correctly noting that the front and rear are different;...
  • Page 146 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Front Brake Lever/Master Cylinder Assembly ..9-2 Rear Brake Pedal/Master Cylinder Assembly ..9-3 Throttle Control ............9-5 Gearshift Pedal............9-6 Reverse Selector/Lock ..........9-6 www.mymowerparts.com...

  • Page 147: Front Brake Lever/Master Cylinder Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Brake Lever/ Master Cylinder Assembly NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Place a shop towel under the brake hose union SP424 4.

  • Page 148: Rear Brake Pedal/Master Cylinder Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the brake hose for cracks and deteriora- 5. Connect the brake hose union bolt (1) to the tion and the condition of the fittings (threaded master cylinder; then with the stopper against and compression).
  • Page 149 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SP433 SP429 INSPECTING ! CAUTION Brake fluid is highly corrosive. Do not spill brake 1. Inspect the master cylinder bore for any fluid on any surface of the ATV. scratches or damage.

  • Page 150: Throttle Control

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the cap screw, lock washer, and washer securing the actuator arm to the throttle control lever. SP435 5. Install the reservoir tank hose; then fill the mas- ter cylinder reservoir with DOT 4 brake fluid and bleed the system.

  • Page 151: Gearshift Pedal

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF680D AL611D 3. Place the two halves of the throttle control onto the handlebars and secure with the two machine Gearshift Pedal screws. The gear shift pedal is attached to a ratchet mecha- nism in the transmission.
  • Page 152 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 2. Route the cable along the upper right frame tube; then attach the reverse selector knob to the 1. Engage the lower cable end in the reverse lock frame with the mounting screw and tighten lever;...
  • Page 153 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications ..........10-2 Torque Conversions ..........10-3 Tightening Torque (General Bolts) ......10-3 www.mymowerparts.com 10-1 Back to TOC...

  • Page 154: Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 BRAKE COMPONENTS Torque Specifications Torque Part Part Bolted To kg-m ft-lb Brake Pad Mounting Pins Caliper Rear Master Cylinder Push Rod DRIVE TRAIN COMPONENTS Push Rod Lock Nut Torque Part...

  • Page 155: Tightening Torque

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 11.2 11.3 11.5 11.6 11.8 11.9 12.0 12.2 12.3 12.5 12.6 10.0 12.8 10.1 12.9 10.2 13.0 10.4 13.1...

  • Page 156: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 11 - TROUBLESHOOTING TABLE OF CONTENTS Engine ..............11-2 Fuel System ............11-6 Electrical..............11-7 Steering/Suspension ..........11-9 Brakes ..............11-10 www.mymowerparts.com 11-1 Back to TOC...

  • Page 157: Engine

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2.
  • Page 158 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine noisy (Noise seems to come from piston) Condition Remedy 1. Piston - cylinder worn 1. Replace - service piston - cylinder 2. Combustion chamber carbon buildup 2. Clean chamber 3.
  • Page 159 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Transmission will not shift Condition Remedy 1. Gearshift cam broken 1. Replace cam 2. Gearshift forks distorted 2. Replace forks 3. Gearshift shaft worn 3. Replace shaft 4. Clutch cable out of adjustment 4.
  • Page 160 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Exhaust smoke dirty or heavy Condition Remedy 1. Piston rings - cylinder worn 1. Replace - service rings - cylinder 2. Valve guides worn 2. Replace guides 3. Cylinder wall scored - scuffed 3.

  • Page 161: Fuel System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel System Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket 4.

  • Page 162: Electrical

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4.
  • Page 163 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Recharge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Repair - replace brushes 4.

  • Page 164: Steering/Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Suspension 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 incorrect 3. Adjust pressure 4.

  • Page 165: Brakes

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1. Replace bushings Problem: Suspension noisy Condition Remedy 1. Cap screws (suspension system) loose 1. Tighten cap screws 2. A-arm-related bushings worn 2.

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